A Hybrid Zeolite Membrane-Based Breakthrough for Simultaneous CO2 Capture and CH4 Upgrading from Biogas

Biogas is an environmentally friendly and sustainable energy resource that can substitute or complement conventional fossil fuels. For practical uses, biogas upgrading, mainly through the effective separation of CO₂ (0.33 nm) and CH₄ (0.38 nm), is required to meet the approximately 90-95% purity of CH₄, while CO₂ should be concomitantly purified. In this study, a high CO₂ perm-selective zeolite membrane was synthesized by heteroepitaxially growing a chabazite (CHA) zeolite seed layer with a synthetic precursor that allowed the formation of all-silica deca-dodecasil 3 rhombohedral (DDR) zeolite (with a pore size of 0.36 × 0.44 nm²). The resulting hydrophobic DDR@CHA hybrid membrane on an asymmetric α-Al₂O₃ tube was thin (ca. 2 μm) and continuous, thus providing both high flux and permselectivity for CO₂ irrespective of the presence or absence of water vapor (the third largest component in the biogas streams). To the best of our knowledge, the CO₂ permeance of (2.9 ± 0.3) × 10^-7 mol m^-2 s^-1 Pa^-1 and CO₂/CH₄ separation factor of ca. 274 ± 73 at a saturated water vapor partial pressure of ca. 12 kPa at 50 °C have the highest CO₂/CH₄ separation performance yet achieved. Furthermore, we explored the membrane module properties of the hybrid membrane in terms of the recovery and purity of both CO₂ and CH₄ under dry and wet conditions. Despite the high intrinsic membrane properties of the current hybrid membrane, reflected by the high permeance and SF, the corresponding module properties indicated that high-performance separation of CO₂ and CH₄ for the desired biogas upgrading was achieved at a limited processing capacity. This supports the importance of understanding the correlation between the membrane and module properties, as this will provide guidance for the optimal operating conditions.

Advances and challenges in the development of nanosheet membranes

The development of highly efficient separation membranes utilizing emerging materials with controllable pore size and minimized thickness could greatly enhance the broad applications of membrane-based technologies. Having this perspective, many studies on the incorporation of nanosheets in membrane fabrication have been conducted, and strong interest in this area has grown over the past decade. This article reviews the development of nanosheet membranes focusing on two-dimensional materials as a continuous phase, due to their promising properties, such as atomic or nanoscale thickness and large lateral dimensions, to achieve improved performance compared to their discontinuous counterparts. Material characteristics and strategies to process nanosheet materials into separation membranes are reviewed, followed by discussions on the membrane performances in diverse applications. The review concludes with a discussion of remaining challenges and future outlook for nanosheet membrane technologies.

Recent Progress in Mixed-Matrix Membranes for Hydrogen Separation

Membrane separation is a compelling technology for hydrogen separation. Among the different types of membranes used to date, the mixed-matrix membranes (MMMs) are one of the most widely used approaches for enhancing separation performances and surpassing the Robeson upper bound limits for polymeric membranes. In this review, we focus on the recent progress in MMMs for hydrogen separation. The discussion first starts with a background introduction of the current hydrogen generation technologies, followed by a comparison between the membrane technology and other hydrogen purification technologies. Thereafter, state-of-the-art MMMs, comprising emerging filler materials that include zeolites, metal-organic frameworks, covalent organic frameworks, and graphene-based materials, are highlighted. The binary filler strategy, which uses two filler materials to create synergistic enhancements in MMMs, is also described. A critical evaluation on the performances of the MMMs is then considered in context, before we conclude with our perspectives on how MMMs for hydrogen separation can advance moving forward.

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.

Platelike MFI Crystals with Controlled Crystal Faces Aspect Ratio

Zeolite crystals offering a short diffusion pathway through the pore network are highly desired for a number of catalytic and molecule separation applications. Herein, we develop a simple synthetic strategy toward reducing the thickness along the b-axis of MFI-type crystals, thus providing a short diffusion path along the straight channel. Our approach combines preliminary aging and a fluoride-assisted low-temperature crystallization. The synthesized MFI crystals are in the micrometer-size range along the a- and c-axis, while the thickness along the b-axis is a few tens of nanometers. The synthesis parameters controlling the formation of platelike zeolite are studied, and the factors controlling the zeolite growth are identified. The synthesis strategy works equally well with all-silica MFI (silicalite-1) and its Al- and Ga-containing derivatives. The catalytic activity of platelike ZSM-5 in the methanol-to-hydrocarbons (MTH) reaction is compared with a commercial nanosized ZSM-5 sample, as the platelike ZSM-5 exhibits a substantially extended lifetime. The synthesis of platelike MFI crystals is successfully scaled up to a kilogram scale.

CO2 capture using membrane contactors: a systematic literature review

With fossil fuel being the major source of energy, CO2 emission levels need to be reduced to a minimal amount namely from anthropogenic sources. Energy consumption is expected to rise by 48% in the next 30 years, and global warming is becoming an alarming issue which needs to be addressed on a thorough technical basis. Nonetheless, exploring CO2 capture using membrane contactor technology has shown great potential to be applied and utilised by industry to deal with post- and pre-combustion of CO2. A systematic review of the literature has been conducted to analyse and assess CO2 removal using membrane contactors for capturing techniques in industrial processes. The review began with a total of 2650 papers, which were obtained from three major databases, and then were excluded down to a final number of 525 papers following a defined set of criteria. The results showed that the use of hollow fibre membranes have demonstrated popularity, as well as the use of amine solvents for CO2 removal. This current systematic review in CO2 removal and capture is an important milestone in the synthesis of up to date research with the potential to serve as a benchmark databank for further research in similar areas of work. This study provides the first systematic enquiry in the evidence to research further sustainable methods to capture and separate CO2.

Microporous framework membranes for precise molecule/ion separations

Microporous framework membranes such as metal-organic framework (MOF) membranes and covalent organic framework (COF) membranes are constructed by the controlled growth of small building blocks with large porosity and permanent well-defined micropore structures, which can overcome the ubiquitous tradeoff between membrane permeability and selectivity; they hold great promise for the enormous challenging separations in energy and environment fields. Therefore, microporous framework membranes are endowed with great expectations as next-generation membranes, and have evolved into a booming research field. Numerous novel membrane materials, versatile manipulation strategies of membrane structures, and fascinating applications have erupted in the last five years. First, this review summarizes and categorizes the microporous framework membranes with pore sizes lower than 2 nm based on their chemistry: inorganic microporous framework membranes, organic-inorganic microporous framework membranes, and organic microporous framework membranes, where the chemistry, fabrications, and differences among these membranes have been highlighted. Special attention is paid to the membrane structures and their corresponding modifications, including pore architecture, intercrystalline grain boundary, as well as their diverse control strategies. Then, the separation mechanisms of membranes are covered, such as diffusion-selectivity separation, adsorption-selectivity separation, and synergetic adsorption-diffusion-selectivity separation. Meanwhile, intricate membrane design to realize synergistic separation and some emerging mechanisms are highlighted. Finally, the applications of microporous framework membranes for precise gas separation, liquid molecule separation, and ion sieving are summarized. The remaining challenges and future perspectives in this field are discussed. This timely review may provide genuine guidance on the manipulation of membrane structures and inspire creative designs of novel membranes, promoting the sustainable development and steadily increasing prosperity of this field.

Highly Ordered Nanochannels in a Nanosheet-Directed Thin Zeolite Nanofilm for Precise and Fast CO2 Separation

Precise molecular and ion separations depend largely on the size and uniformity of the nanochannels in a defect-free microporous nanofilm. Ordered and perpendicular nanochannels with uniform pore size are assembled into a continuous and defect-free film by a "gel nuclei-less" route. The ultrathin (<50 nm) zeolite nanosheets seeding layer induces the formation of defect-free zeolite nanofilms (500-800 nm) with preferential [100] orientation well-aligned to the transport pathway. The large-area and thin silicoaluminophosphate-34 (SAPO-34) nanofilm consisting of uniform and straight nanochannels shows a milestone CO₂ permeance of ≈1.0 × 10^-5 mol (m² s Pa)^-1 and high CO₂ /CH₄ and CO₂ /N₂ selectivities of 135 and 41 in equimolar binary mixtures at room temperature and 0.2 MPa feed pressure, respectively. These results suggest that highly oriented and thin SAPO-34 nanofilms prepared from nanosheets might have great potential for CO₂ capture from natural gas, biogas, and flue gas.

Unobstructed Ultrathin Gas Transport Channels in Composite Membranes by Interfacial Self-Assembly

Ultrathin unobstructed gas transport channels through the membrane selective layer are constructed in mixed matrix membranes (MMMs) by using gravity-induced interface self-assembly of poly(vinylamine) and polymer-modified MIL-101(Cr). For CO₂ /N₂ (15/85 by volume) mixed gas, the MMMs achieve a high CO₂ permeance of 823 gas permeation units and CO₂ /N₂ selectivity of 242 at 0.5 MPa. Based on economic analyses, a two-stage membrane process can achieve gas separation and economic targets.

Gelless Secondary Growth of Zeolitic Aluminophosphate Membranes on Porous Supports with High Performance in CO2 /CH4 Separation

Zeolitic aluminophosphate, a three-dimensional microporous material, with an average pore size of 0.38 nm is good candidate for molecular sieve application in CO₂ gas separation. The separation of CO₂ /CH₄ gas mixtures for precombustion processes is desirable from the standpoint of both environmental concerns and energy efficiency. This study concerns an environmentally friendly method to synthesize zeolitic aluminophosphate thin films on various configurations and low-cost kaolin porous substrates with high performance in the separation of CO₂ /CH₄ mixtures. The membranes are prepared by a gelless seed growth method that uses lower amounts of chemicals, forms no liquid gel, chemical waste, or byproducts and generates no washing water. The obtained membranes show very high selectivity for CO₂ with a CO₂ /CH₄ separation factor above 1000 in the separation of CO₂ /CH₄ gas mixtures.

Organic-inorganic hybrids for CO2 sensing, separation and conversion

Motivated by the air pollution that skyrocketed in numerous regions around the world, great effort was placed on discovering new classes of materials that separate, sense or convert CO₂ in order to minimise impact on human health. However, separation, sensing and conversion are not only closely intertwined due to the ultimate goal of improving human well-being, but also because of similarities in material prerequisites -e.g. affinity to CO₂. Partly inspired by the unrivalled performance of complex natural materials, manifold inorganic-organic hybrids were developed. One of the most important characteristics of hybrids is their design flexibility, which results from the combination of individual constituents with specific functionality. In this review, we discuss commonly used organic, inorganic, and inherently hybrid building blocks for applications in separation, sensing and catalytic conversion and highlight benefits like durability, activity, low-cost and large scale fabrication. Moreover, we address obstacles and potential future developments of hybrid materials. This review should inspire young researchers in chemistry, physics and engineering to identify and overcome interdisciplinary research challenges by performing academic research but also - based on the ever-stricter emission regulations like carbon taxes - through exchanges between industry and science.

Facile Preparation of Bilayer Titanium Silicate (TS-1) Zeolite Membranes by Periodical Secondary Growth

A facile periodical secondary growth method, based on conventional secondary growth, is proposed to prepare bilayer TS-1 membranes. The novel periodical secondary growth consists of two or several periods, which involve three steps: the temperature is programmed to a desired crystallization temperature as the first stage, followed by holding for a certain duration, and finally cooling to room temperature. This periodical crystallization model enables a bilayer TS-1 membrane to be produced, while the conventional secondary growth method produces a monolayer TS-1 membrane. The bilayer TS-1 membrane exhibits a superior defect-free structure and hydrophobic properties, as illustrated by SEM, gas permeance, pore size distribution analysis, and water contact angle measurement. It displays an earlier desalination separation factor compared to the monolayer TS-1 membrane. This work demonstrates that the periodical secondary growth is an advanced approach for preparing a bilayer zeolite membrane with excellent properties.

One-Pot Synthesis of High-Flux b-Oriented MFI Zeolite Membranes for Xe Recovery

We demonstrate that b-oriented MFI (Mobil Five) zeolite membranes can be manufactured by in situ crystallization using an intermediate amorphous SiO₂ layer. The improved in-plane growth by using a zeolite growth modifier leads to fusion of independent crystals and eliminates boundary gaps, giving good selectivity in the separation of CO₂/Xe mixtures. The fast diffusion of CO₂ dominates the overall membrane selectivity toward the CO₂/Xe mixture. Because of the straight and short [010] channels, the obtained CO₂ permeation fluxes are several orders of magnitude higher than those of carbon molecular sieving membranes and polymeric membranes, opening opportunities for Xe recovery from waste anesthetic gas.

Uniformly Oriented Zeolite ZSM-5 Membranes with Tunable Wettability on a Porous Ceramic

Facile fabrication of well-intergrown, oriented zeolite membranes with tunable chemical properties on commercially proven substrates is crucial to broadening their applications for separation and catalysis. Rationally determined electrostatic adsorption can enable the direct attachment of a b-oriented silicalite-1 monolayer on a commercial porous ceramic substrate. Homoepitaxially oriented, well-intergrown zeolite ZSM-5 membranes with a tunable composition of Si/Al=25-∞ were obtained by secondary growth of the monolayer. Intercrystallite defects can be eliminated by using Na+ as the mineralizer to promote lateral crystal growth and suppress surface nucleation in the direction of the straight channels, as evidenced by atomic force microscopy measurements. Water permeation testing shows tunable wettability from hydrophobic to highly hydrophilic, giving the potential for a wide range of applications.

Ultra-thin enzymatic liquid membrane for CO2 separation and capture

The limited flux and selectivities of current carbon dioxide membranes and the high costs associated with conventional absorption-based CO₂ sequestration call for alternative CO₂ separation approaches. Here we describe an enzymatically active, ultra-thin, biomimetic membrane enabling CO₂ capture and separation under ambient pressure and temperature conditions. The membrane comprises a ~18-nm-thick close-packed array of 8 nm diameter hydrophilic pores that stabilize water by capillary condensation and precisely accommodate the metalloenzyme carbonic anhydrase (CA). CA catalyzes the rapid interconversion of CO₂ and water into carbonic acid. By minimizing diffusional constraints, stabilizing and concentrating CA within the nanopore array to a concentration 10× greater than achievable in solution, our enzymatic liquid membrane separates CO₂ at room temperature and atmospheric pressure at a rate of 2600 GPU with CO₂/N₂ and CO₂/H₂ selectivities as high as 788 and 1500, respectively, the highest combined flux and selectivity yet reported for ambient condition operation.

Porous membranes show great promise for CO₂ separation and capture, but are currently limited by a trade-off between permeance and selectivity. Here, the authors fabricate a bio-inspired, ultra-thin enzymatic liquid membrane that displays exceptional CO₂ permeability and selectivity under ambient conditions.

Synthesis of a ZSM-5/NaA hybrid zeolite membrane using kaolin as a modification layer

A kaolin modification layer, which makes the surface of the support smooth and covers the defects on the support, not only attracts Si/Al active materials to the surface of the ceramic tube, but also dissolves under alkaline conditions to assist the growth of zeolite membranes.

Adsorption of Butanol and Water Vapors in Silicalite-1 Films with a Low Defect Density

Pure silica zeolites are potentially hydrophobic and have therefore been considered to be interesting candidates for separating alcohols, e.g., 1-butanol, from water. Zeolites are traditionally synthesized at high pH, leading to the formation of intracrystalline defects in the form of silanol defects in the framework. These silanol groups introduce polar adsorption sites into the framework, potentially reducing the adsorption selectivity toward alcohols in alcohol/water mixtures. In contrast, zeolites prepared at neutral pH using the fluoride route contain significantly fewer defects. Such crystals should show a much higher butanol/water selectivity than crystals prepared in traditional hydroxide (OH^-) media. Moreover, silanol groups are present at the external surface of the zeolite crystals; therefore, minimizing the external surface of the studied adsorbent is important. In this work, we determine adsorption isotherms of 1-butanol and water in silicalite-1 films prepared in a fluoride (F^-) medium using in situ attenuated total reflectance-Fourier transform infrared (ATR-FTIR) spectroscopy. This film was composed of well intergrown, plate-shaped b-oriented crystals, resulting in a low external area. Single-component adsorption isotherms of 1-butanol and water were determined in the temperature range of 35-80 °C. The 1-butanol isotherms were typical for an adsorbate showing a high affinity for a microporous material and a large increase in the amount adsorbed at low partial pressures of 1-butanol. The Langmuir-Freundlich model was successfully fitted to the 1-butanol isotherms, and the heat of adsorption was determined. Water showed a very low affinity for the adsorbent, and the amounts adsorbed were very similar to previous reports for large silicalite-1 crystals prepared in a fluoride medium. The sample also adsorbed much less water than did a reference silicalite-1(OH^-) film containing a high density of internal defects.The results show that silicalite-1 films prepared in a F^- medium with a low density of defects and external area are very promising for the selective recovery of 1-butanol from aqueous solutions.

Mixed-Matrix Membranes Containing Carbon Nanotubes Composite with Hydrogel for Efficient CO2 Separation

In this study, a carbon nanotubes composite coated with N-isopropylacrylamide hydrogel (NIPAM-CNTs) was synthesized. Mixed-matrix membranes (MMMs) were fabricated by incorporating NIPAM-CNTs composite filler into poly(ether-block-amide) (Pebax MH 1657) matrix for efficient CO₂ separation. The as-prepared NIPAM-CNTs composite filler mainly plays two roles: (i) The extraordinary smooth one-dimensional nanochannels of CNTs act as the highways to accelerate CO₂ transport through membranes, increasing CO₂ permeability; (ii) The NIPAM hydrogel layer coated on the outer walls of CNTs acts as the super water absorbent to increase water content of membranes, appealing both CO₂ permeability and CO₂/gas selectivity. MMM containing 5 wt % NIPAM-CNTs exhibited the highest CO₂ permeability of 567 barrer, CO₂/CH₄ selectivity of 35, and CO₂/N₂ selectivity of 70, transcending 2008 Robeson upper bound line. The improved CO₂ separation performance of MMMs is mainly attributed to the construction of the efficient CO₂ transport pathways by NIPAM-CNTs. Thus, MMMs incorporated with NIPAM-CNTs composite filler can be used as an excellent membrane material for efficient CO₂ separation.