Optimization of the gas separation performance of polyurethane–zeolite 3A and ZSM-5 mixed matrix membranes using response surface methodology

Recent advancements in polyurethane-based membranes for gas separation

Gas separation membranes are critical in a variety of environmental research and industrial applications. These membranes are designed to selectively allow some gases to flow while blocking others, allowing for the separation and purification of gases for a variety of applications. Therefore, the demand for fast and energy-efficient gas separation techniques is of central interest for many chemical and energy production diligences due to the intensified levels of greenhouse and industrial gases. This encourages the researchers to innovate techniques for capturing and separating these gases, including membrane separation techniques. Polymeric membranes play a significant role in gas separations by capturing gases from the fuel combustion process, purifying chemical raw material used for plastic production, and isolating pure and noncombustible gases. Polyurethane-based membrane technology offers an excellent knack for gas separation applications and has also been considered more energy-efficient than conventional phase change separation methodologies. This review article reveals a thorough delineation of the current developments and efforts made for PU membranes. It further explains its uses for the separation of valuable gases such as carbon dioxide (CO2), hydrogen (H2), nitrogen (N2), methane (CH4), or a mixture of gases from a variety of gas spillages. Polyurethane (PU) is an excellent choice of material and a leading candidate for producing gas-separating membranes because of its outstanding chemical chemistry, good mechanical abilities, higher permeability, and variable microstructure. The presence of PU improves several characteristics of gas-separating membranes. Selectivity and separation efficiency of PU-centered membranes are enhanced through modifications such as blending with other polymers, use of nanoparticles (silica, metal oxides, alumina, zeolite), and interpenetrating polymer networks (IPNs) formation. This manuscript critically analyzes the various gas transport methods and selection criteria for the fabrication of PU membranes. It also covers the challenges facing the development of PU-membrane-based separation procedures.

A thermodynamic study on relationship between gas separation properties and microstructure of polyurethane membranes

The lattice fluid (LF) thermodynamic model and extended Vrentas' free-volume (E-VSD) theory were coupled to study the gas separation properties of the linear thermoplastic polyurethane (TPU) membranes with different chemical structures by analyzing their microstructures. A set of characteristic parameters were extracted using the repeating unit of the TPU samples and led to prediction of reliable polymer densities (AARD < 6%) and gas solubilities. The viscoelastic parameters, which were obtained from the DMTA analysis, were also estimated the gas diffusion vs. temperature, precisely. The degree of microphase mixing based on the DSC analysis was in order: TPU-1 (4.84 wt%) < TPU-2 (14.16 wt%) < TPU-3 (19.92 wt%). It was found that the TPU-1 membrane had the highest degree of crystallinity, but showed higher gas solubilities and permeabilities because this membrane has the least degree of microphase mixing. These values, in combination with the gas permeation results, showed that the content of the hard segment along with the degree of microphase mixing and other microstructural parameters like crystallinity were the determinative parameters.

RSM Modeling and Optimization of CO2 Separation from High CO2 Feed Concentration over Functionalized Membrane

The challenges in developing high CO₂ gas fields are governed by several factors such as reservoir condition, feed gas composition, operational pressure and temperature, and selection of appropriate technologies for bulk CO₂ separation. Thus, in this work, we report an optimization study on the separation of CO₂ from CH₄ at high CO₂ feed concentration over a functionalized mixed matrix membrane using a statistical tool, response surface methodology (RSM) statistical coupled with central composite design (CCD). The functionalized mixed matrix membrane containing NH₂-MIL-125 (Ti) and 6FDA-durene, fabricated in our previous study, was used to perform the separation performance under three operational parameters, namely, feed pressure, temperature, and CO₂ feed concentration, ranging from 3.5–12.5 bar, 30.0–50.0 °C and 15–70 mol%, respectively. The CO₂ permeability and CO₂/CH₄ separation factor obtained from the experimental work were varied from 293.2–794.4 Barrer and 5.3–13.0, respectively. In addition, the optimum operational parameters were found at a feed pressure of 12.5 bar, a temperature of 34.7 °C, and a CO₂ feed concentration of 70 mol%, which yielded the highest CO₂ permeability of 609.3 Barrer and a CO₂/CH₄ separation factor of 11.6. The average errors between the experimental data and data predicted by the model for CO₂ permeability and CO₂/CH₄ separation factor were 5.1% and 3.3%, respectively, confirming the validity of the proposed model. Overall, the findings of this work provide insights into the future utilization of NH₂-MIL-125 (Ti)/6FDA-based mixed matrix membranes in real natural gas purification applications.

Removal of SO2 from flue gas using blast furnace dust as an adsorbent

To control the SO₂ emission and achieve the target of "waste controlled by waste", a novel desulfurization method with blast furnace dust slurry was proposed. The effects of reaction temperature, oxygen concentration, and solid-liquid ratio on SO₂ removal efficiency were investigated. The optimal conditions were reaction temperature of 35 ℃, oxygen concentration of 10 vol.%, and solid-liquid ratio of 0.5 g/300 mL. Under the optimal conditions, the desulfurization efficiency reached 100% for 4 h. Response surface methodology (RSM) results showed that oxygen concentration significantly influenced the SO₂ removal efficiency. Finally, the possible desulfurization mechanism of blast furnace dust was proposed based on the EDX, XRD, SEM-EDS, ICP, and IC. The blast furnace dust (main components are CaZn₈(SO₄)₂(OH)₁₂Cl₂·(H₂O)₉, Mn_6.927Si₆O₁₅·(OH)₈, ZnO, Fe₂O₃) reacted with H⁺ to form Zn²⁺, Fe³⁺, and Mn²⁺ which shows a key effect on the SO₂ liquid catalytic oxidation. This study provides a promising, feasible, and low-cost desulfurization technology by reusing blast furnace dust.

Investigating the properties and performance of 3A molecular sieves as an adsorbent to prevent coke formation in olefin dehydration process

To study the affinity of 3A aluminosilicate adsorbents to prevent oligomerization of olefin molecules and forming green oil, physical and chemical properties of 3A molecular sieves are measured by using characterization techniques such as temperature-programmed desorption (TPD), nitrogen (N2) and water adsorptions, X-ray diffraction (XRD), X-ray fluorescence (XRF), crushing strength, and carbon dioxide (CO2) adsorption. Moreover, coke formation affinities of the understudy adsorbents are evaluated in a bench-scale system using 1-butene and 1,3-butadiene at temperatures of 220 and 260 °C, and outcomes are validated against the actual data gathered from an industrial scale olefin dehydration plant. Results confirm that the type of binder and the amount of ion exchange affect the performance of a 3A molecular sieve nominated for dehydrating olefinic streams. The binder with the least amount of acidity is preferred, and at least 35% of Na ions of the 4A zeolite should be exchanged with K ions to make it applicable for synthesizing an appropriate 3A molecular sieve. Furthermore, to control the oligomerization and inhibit green oil formation, the CO2 adsorption and acidity of Trisiv shape molecular sieves with the sizes of 1/4 inch should be less than 0.5 wt % and 1.7 mmol NH3/g, respectively. For extrudate shape with the sizes of 1/16 inch CO2 adsorption and acidity should be less than 0.2 wt % and 2.2 mmol NH3/g, respectively.

P84/ZCC Hollow Fiber Mixed Matrix Membrane with PDMS Coating to Enhance Air Separation Performance

This research introduces zeolite carbon composite (ZCC) as a new filler on polymeric membranes based on the BTDA-TDI/MDI (P84) co-polyimide for the air separation process. The separation performance was further improved by a polydimethylsiloxane (PDMS) coating to cover up the surface defect. The incorporation of 1 wt% ZCC into P84 co-polyimide matrix enhanced the O2 permeability from 7.12 to 18.90 Barrer (2.65 times) and the O2/N2 selectivity from 4.11 to 4.92 Barrer (19.71% improvement). The PDMS coating on the membrane further improved the O2/N2 selectivity by up to 60%. The results showed that the incorporation of ZCC and PDMS coating onto the P84 co-polyimide membrane was able to increase the overall air separation performance.

Identification of the Interfacial Surface in Separation of Two-Phase Multicomponent Systems

The area of the contact surface of phases is one of the main hydrodynamic indicators determining the separation and heat and mass transfer equipment calculations. Methods of evaluating this indicator in the separation of multicomponent two-phase systems were considered. It was established that the existing methods for determining the interfacial surface are empirical ones, therefore limited in their applications. Consequently, the use of the corresponding approaches is appropriate for certain technological equipment only. Due to the abovementioned reasons, the universal analytical formula for determining the interfacial surface was developed. The approach is based on both the deterministic and probabilistic mathematical models. The methodology was approved on the example of separation of two-phase systems considering the different fractional distribution of dispersed particles. It was proved that the area of the contact surface with an accuracy to a dimensionless ratio depends on the volume concentration of the dispersed phase and the volume of flow. The separate cases of evaluating the contact area ratio were considered for different laws of the fractional distribution of dispersed particles. As a result, the dependence on the identification of the abovementioned dimensionless ratio was proposed, as well as its limiting values were determined. Finally, a need for the introduction of the correction factor was substantiated and practically proved on the example of mass-transfer equipment.