Pore size engineering of cost-effective all-nanoporous multilayer membranes for propane/propylene separation

In this study, a new multi-layer hybrid nanocomposite membrane named MFI/GO/ZIF-8 has been synthesized. This membrane combines three nanoporous materials with different morphologies in one membrane without using polymer materials. This allows access to a previously accessible region of very high permeability and selectivity properties. In addition to introducing a new and efficient MFI/GO/ZIF-8 membrane in this work, controlling the pore size of the zeolite layer has been investigated to increase the selectivity and permeability of propylene. The membrane was made using a solvent-free hydrothermal method and a layer-by-layer deposition method. To control the pore size of the MFI layer, a two-step synthesis strategy has been implemented. In the first step, three key parameters, including crystallization time, NaOH concentration and aging time of initial suspension, are controlled. In the second step, the effect of three additional parameters including hydrothermal time, hydrothermal temperature and NH4F concentration has been investigated. The results show that the optimal pore size has decreased from 177.8 nm to 120.53 nm (i.e., 32.2%). The MFI/GO/ZIF-8 membrane with fine-tuned crystal size in the zeolite layer was subjected to detailed tests for propylene selectivity and permeability. The structural characteristics of the membrane were also performed using FT-IR, XRD, FESEM and EDS techniques. The results show that the synergistic interaction between the three layers in the nanocomposite membrane significantly improves the selectivity and permeability of propylene. The permeability and selectivity of propylene increased from 50 to 60 GPU and from 136 to 177, respectively, before and after precise crystal size control. MFI/GO/ZIF-8 membrane by controlling the pore size of the zeolite layer shows a significant increase of 23.1% in selectivity and 16.7% in propylene permeability compared to the initial state. Also, due to the precise synthesis method, the absence of solvent and the use of cheap support, the prepared membrane is considered an environmentally friendly and low-cost membrane. This study emphasizes the potential of increasing the selectivity and permeability of propylene in the MFI/GO/ZIF-8 hybrid membrane by controlling the crystal size of the zeolite layer.

High-Performance FAU Zeolite Membranes Derived from Nano-Seeds for Gas Separation

In this study, high-performance FAU (NaY type) zeolite membranes were successfully synthesized using small-sized seeds of 50 nm, and their gas separation performance was systematically evaluated. Employing nano-sized NaY seeds and an ultra-dilute reaction solution with a molar composition of 80 Na2O: 1Al2O3: 19 SiO2: 5000H2O, the effects of synthesis temperature, crystallization time, and porous support (α-Al2O3 or mullite) on the formation of FAU membranes were investigated. The results illustrated that further extending the crystallization time or increasing the synthesis temperature led to the formation of a NaP impurity phase on the FAU membrane layer. The most promising FAU membrane with a thickness of 2.7 µm was synthesized on an α-Al2O3 support at 368 K for 8 h and had good reproducibility. The H2 permeance of the membrane was as high as 5.34 × 10-7 mol/(m2 s Pa), and the H2/C3H8 and H2/i-C4H10 selectivities were 183 and 315, respectively. The C3H6/C3H8 selectivity of the membrane was as high as 46, with a remarkably high C3H6 permeance of 1.35 × 10-7 mol/(m2 s Pa). The excellent separation performance of the membrane is mainly attributed to the thin, defect-free membrane layer and the relatively wide pore size (0.74 nm).

Fabrication of Polycrystalline Zeolitic Imidazolate Framework Membranes by a Vapor-Phase Seeding Method

The reliable fabrication of polycrystalline zeolitic imidazolate framework (ZIF) membranes continues to pose challenges for their industrial applications. Here, we present a vapor-phase seeding approach that integrates atomic layer deposition (ALD) with ligand vapor treatment to synthesize ZIF membranes with high propylene/propane separation performance. This method began with depositing a ZnO coating onto the support surface via ALD. The support underwent treatment with 2-methylimidazole vapor to transform ZnO to ZIF-8, forming the seed layer. Subsequent secondary growth was employed at near-room temperature, allowing the seeds to grow into a continuous membrane. ZIF-8 membranes made on macroporous ceramic support by this method consistently demonstrated propylene permeances above 1 × 10-8 mol Pa-1 m-2 s-1 and a propylene/propane separation factor exceeding 50. Moreover, we demonstrated the effectiveness of the vapor-phase seeding method in producing the ZIF-67 membrane.

Advanced carbon molecular sieve membranes derived from molecularly engineered cross-linkable copolyimide for gas separations

Carbon molecular sieve (CMS) membranes with precise molecular discrimination ability and facile scalability are attractive next-generation membranes for large-scale, energy-efficient gas separations. Here, structurally engineered CMS membranes derived from a tailor-made cross-linkable copolyimide with kinked structure are reported. We demonstrate that combining two features, kinked backbones and cross-linkable backbones, to engineer polyimide precursors while controlling pyrolysis conditions allows the creation of CMS membranes with improved gas separation performance. Our results indicate that the CMS membranes provide a versatile platform for a broad spectrum of challenging gas separations. The gas transport properties of the resulting CMS membranes are interpreted in terms of a model reflecting both molecular sieving Langmuir domains and a disordered continuous phase, thereby providing insight into structure evolution from the cross-linkable polyimide precursor to a final CMS membrane. With this understanding of CMS membrane structure and separation performance, these systems are promising for environmentally friendly gas separations.

Ultrathin Covalent Organic Framework Membranes via a Multi-Interfacial Engineering Strategy for Gas Separation

Covalent organic frameworks (COFs) are promising membrane materials due to their high porosity, ordered arrangements, and high stability. However, the relatively large pore size and complicated membrane preparation processes of COFs limit their applications in sieving small gas molecules, even at a lab scale. Herein, a multi-interfacial engineering strategy is proposed, that is, direct layer-by-layer interfacial reaction of two COFs (TpPa-SO₃ H and TpTG_Cl ) with different pore sizes to form narrowed apertures at the COF-COF interfaces atop a relatively large-pore COF (COF-LZU1) film. At 423 K, one fabricated 155 nm-thick ultrathin COF membrane displays H₂ permeance as high as 2163 gas permeation units (GPU) and a H₂ /CO₂ selectivity of 26, transcending the 2008 Robeson upper bound. This strategy not only provides high-performance membrane candidates for H₂ separation, but also enlightens the interfacial engineering and pore engineering manipulation for other COFs, porous polymers, and their membranes.

Design and Evaluation of Two-Stage Membrane-Separation Processes for Propylene–Propane Mixtures

Propylene is industrially produced in a mixture with propane and generally separated from the mixture via distillation. However, because distillation is an energy-consuming process, a more efficient separation process should be developed to mitigate both carbon dioxide (CO₂) emissions and production costs. In this study, a two-stage membrane-separation process was designed, and its CO₂ emission and production costs were evaluated. The separation processes were designed to minimize energy consumption using different membrane combinations (two recently developed membranes each). To evaluate the separation processes using various membrane combinations, two indicators, i.e., CO₂ emissions and total annual costs (TACs), were estimated based on the process simulation (Pro/II, version 10.1.1) results, including energy consumptions, operation expenditure, and capital expenditure. These results were compared to the distillation processes as benchmarks, and the advantages of the membrane-separation process were discussed. In the comparison, carbon taxes were implemented for assessing these two independent indicators as a single indicator, i.e., TAC with carbon tax. Furthermore, using the same scheme, model membranes were also employed in the two-stage membrane-separation process as case studies of technological forecasts.

A Review on Polymer Precursors of Carbon Molecular Sieve Membranes for Olefin/Paraffin Separation

Carbon molecular sieve (CMS) membranes have been developed to replace or support energy-intensive cryogenic distillation for olefin/paraffin separation. Olefin and paraffin have similar molecular properties, but can be separated effectively by a CMS membrane with a rigid, slit-like pore structure. A variety of polymer precursors can give rise to different outcomes in terms of the structure and performance of CMS membranes. Herein, for olefin/paraffin separation, the CMS membranes derived from a number of polymer precursors (such as polyimides, phenolic resin, and polymers of intrinsic microporosity, PIM) are introduced, and olefin/paraffin separation properties of those membranes are summarized. The effects from incorporation of inorganic materials into polymer precursors and from a pyrolysis process on the properties of CMS membranes are also reviewed. Finally, the prospects and future directions of CMS membranes for olefin/paraffin separation and aging issues are discussed.

Recent Progress in a Membrane-Based Technique for Propylene/Propane Separation

The similar physico-chemical properties of propylene and propane molecules have made the separation process of propylene/propane challenging. Membrane separation techniques show substantial prospects in propylene/propane separation due to their low energy consumption and investment costs, and they have been proposed to replace or to be combined with the conventional cryogenic distillation process. Over the past decade, organosilica membranes have attracted considerable attention due to their significant features, such as their good molecular sieving properties and high hydrothermal stability. In the present review, holistic insight is provided to summarize the recent progress in propylene/propane separation using polymeric, inorganic, and hybrid membranes, and a particular inspection of organosilica membranes is conducted. The importance of the pore subnano-environment of organosilica membranes is highlighted, and future directions and perspectives for propylene/propane separation are also provided.

CO2/CH4 and He/N2 Separation Properties and Water Permeability Valuation of Mixed Matrix MWCNTs-Based Cellulose Acetate Flat Sheet Membranes: A Study of the Optimization of the Filler Material Dispersion Method

The main scope of this work is to develop nano-carbon-based mixed matrix cellulose acetate membranes (MMMs) for the potential use in both gas and liquid separation processes. For this purpose, a variety of mixed matrix membranes, consisting of cellulose acetate (CA) polymer and carbon nanotubes as additive material were prepared, characterized, and tested. Multi-walled carbon nanotubes (MWCNTs) were used as filler material and diacetone alcohol (DAA) as solvent. The first main objective towards highly efficient composite membranes was the proper preparation of agglomerate-free MWCNTs dispersions. Rotor-stator system (RS) and ultrasonic sonotrode (USS) were used to achieve the nanofillers’ dispersion. In addition, the first results of the application of the three-roll mill (TRM) technology in the filler dispersion achieved were promising. The filler material, MWCNTs, was characterized by scanning electron microscopy (SEM) and liquid nitrogen (LN₂) adsorption-desorption isotherms at 77 K. The derivatives CA-based mixed matrix membranes were characterized by tensile strength and water contact angle measurements, impedance spectroscopy, gas permeability/selectivity measurements, and water permeability tests. The studied membranes provide remarkable water permeation properties, 12–109 L/m²/h/bar, and also good separation factors of carbon dioxide and helium separations. Specifically, a separation factor of 87 for 10% He/N₂ feed concentration and a selectivity value of 55.4 for 10% CO₂/CH₄ feed concentration were achieved.

Membrane-Based Olefin/Paraffin Separations

Efficient olefin/paraffin separation is a grand challenge because of their similar molecular sizes and physical properties, and is also a priority in the modern chemical industry. Membrane separation technology has been demonstrated as a promising technology owing to its low energy consumption, mild operation conditions, tunability of membrane materials, as well as the integration of physical and chemical mechanisms. In this work, inspired by the physical mechanism of mass transport in channel proteins and the chemical mechanism of mass transport in carrier proteins, recent progress in channel-based and carrier-based membranes toward olefin/paraffin separations is summarized. Further, channel-based membranes are categorized into membranes with network structures and with framework structures according to the morphology of channels. The separation mechanisms, separation performance, and membrane stability in channel-based and carrier-based membranes are elaborated. Future perspectives toward membrane-based olefin/paraffin separation are proposed.

A Bibliometric Survey of Paraffin/Olefin Separation Using Membranes

Bibliometric studies allow to collect, organize and process information that can be used to guide the development of research and innovation and to provide basis for decision-making. Paraffin/olefin separations constitute an important industrial issue because cryogenic separation methods are frequently needed in industrial sites and are very expensive. As a consequence, the use of membrane separation processes has been extensively encouraged and has become an attractive alternative for commercial separation processes, as this may lead to reduction of production costs, equipment size, energy consumption and waste generation. For these reasons, a bibliometric survey of paraffin/olefin membrane separation processes is carried out in the present study in order to evaluate the maturity of the technology for this specific application. Although different studies have proposed the use of distinct alternatives for olefin/paraffin separations, the present work makes clear that consensus has yet to be reached among researchers and technicians regarding the specific membranes and operation conditions that will make these processes scalable for large-scale commercial applications.

Alternatives to Cryogenic Distillation: Advanced Porous Materials in Adsorptive Light Olefin/Paraffin Separations

As primary feedstocks in the petrochemical industry, light olefins such as ethylene and propylene are mainly obtained from steam cracking of naphtha and short chain alkanes (ethane and propane). Due to their similar physical properties, the separations of olefins and paraffins-pivotal processes to meet the olefin purity requirement of downstream processing-are typically performed by highly energy-intensive cryogenic distillation at low temperatures and high pressures. To reduce the energy input and save costs, adsorptive olefin/paraffin separations have been proposed as promising techniques to complement or even replace cryogenic distillation, and growing efforts have been devoted to developing advanced adsorbents to fulfill this challenging task. In this Review, a holistic view of olefin/paraffin separations is first provided by summarizing how different processes have been established to leverage the differences between olefins and paraffins for effective separations. Subsequently, recent advances in the development of porous materials for adsorptive olefin/paraffin separations are highlighted with an emphasis on different separation mechanisms. Last, a perspective on possible directions to push the limit of the research in this field is presented.

Thin Composite Carbon Molecular Sieve Membranes from a Polymer of Intrinsic Microporosity Precursor

Ultra-thin composite carbon molecular sieve (CMS) membranes were fabricated on well-defined inorganic alumina substrates using a polymer of intrinsic microporosity (PIM) as a precursor. Details of the pyrolysis-related structural development were elucidated using focused-beam, interference-enhanced spectroscopic ellipsometry (both in the UV-vis and IR range), which allowed accurate determination of the film thickness, optical properties as well as following the chemical transformations. The pyrolysis-induced collapse of thin and bulk PIM-derived CMS membranes was compared with CMS made from a well-known non-PIM precursor 6FDA-DABA. Significant differences between the PIM and non-PIM precursors were discovered and explained by a much larger possible volume contraction in the PIM. In spite of the differences, surprisingly, the gas separation properties did not fundamentally differ. The high-temperature collapse of the initially amorphous and isotropic precursor structure was accompanied by a significant molecular orientation within the formed turbostratic carbon network guided by the laterally constraining presence of the substrate. This manifested itself in the development of uniaxial optical anisotropy, which was shown to correlate with increases in gas separation selectivity for multiple technologically important gas pairs. Reduction of CMS skin thickness significantly below ∼1 μm induced large losses in permeability coefficients with only small to moderate effects on selectivity. Remarkably, skin thickness reduction and physical aging seemed to superimpose onto the same trend, which explains and strengthens some of the earlier fundamental insights.

Ultrathin Carbon Molecular Sieve Films and Room-Temperature Oxygen Functionalization for Gas-Sieving

Inorganic membranes based on carbon molecular sieve (CMS) films hosting slit-like pores can yield high molecular selectivity with a sub-angstrom resolution in molecular differentiation and therefore are highly attractive for energy-efficient separations. However, the selective layer thickness of the state-of-the-art CMS membranes for gas separation is more than 1 μm, yielding low gas permeance. Also, there is no room-temperature functionalization route for the modification of the pore-size-distribution of CMS to increase the molecular selectivity. In this context, we report two novel fabrication routes, namely, transfer and masking techniques, leading to CMS films with thicknesses as small as 100 nm, yielding attractive gas-sieving performances with H₂ permeance reaching up to 3060 gas permeation unit (GPU). Further, a rapid and highly tunable room-temperature ozone treatment-based postsynthetic modification is reported, shrinking the electron density gap in the nanopores by a fraction of an angstrom and improving gas selectivities by several folds. The optimized membranes yielded H₂ permeance of 507 GPU and H₂/CH₄ selectivity of 50.7.

Zeolitic Imidazolate Framework Membranes for Light Olefin/Paraffin Separation

Propylene/propane and ethylene/ethane separations are performed by energy-intensive distillation processes, and membrane separation may provide substantial energy and capital cost savings. Zeolitic imidazolate frameworks (ZIFs) have emerged as promising membrane materials for olefin/paraffin separation due to their tunable pore size and chemistry property, and excellent chemical and thermal stability. In this review, we summarize the recent advances on ZIF membranes for propylene/propane and ethylene/ethane separations. Membrane fabrication methods such as in situ crystallization, seeded growth, counter-diffusion synthesis, interfacial microfluidic processing, vapor-phase and current-driven synthesis are presented. The gas permeation and separation characteristics and membrane stability are also discussed.