CHA-DDR Zeolite Membrane for CO2 Separation
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Solution Overview
Problem
Conventional methods for manufacturing DDR zeolite membranes are difficult to reproduce and result in membranes with high thickness, limiting their industrial application due to challenges in securing reproducibility and achieving thin film thickness for effective carbon dioxide separation.
Innovation Solution
A CHA-DDR type zeolite membrane is developed, comprising a first layer with a CHA structure and a second layer with a DDR structure, manufactured using a novel method involving hydrothermal synthesis with specific precursor solutions and calcination processes, achieving a thin film thickness of 100 nm to 5 μm and high reproducibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional manufacturing methods are used for DDR zeolite membranes, then the membranes can be produced, but the thickness is high and reproducibility is poor
Solution Approach 1:
The membrane is divided into two distinct layers: a first layer containing both CHA and DDR structures, and a second layer containing primarily DDR structure. This segmentation allows each layer to be optimized independently - the first layer provides structural foundation and controlled thickness (50-2000 nm), while the second layer provides the desired DDR separation properties (10-2000 nm), achieving both thin overall thickness and high reproducibility.
Solution Approach 2:
The invention uses a composite zeolite structure combining CHA and DDR crystal structures in a layered configuration. The CHA-DDR composite membrane leverages the complementary properties of both structures - CHA provides structural stability and template directing capability, while DDR provides the desired gas separation properties, resulting in a membrane with controlled thickness and high reproducibility.
2Length of moving object
If the membrane thickness is reduced to improve separation efficiency, then carbon dioxide separation performance is enhanced, but manufacturing reproducibility becomes more difficult
Solution Approach 1:
The first layer is formed first with controlled thickness (50-2000 nm) containing CHA and DDR structures, establishing a stable foundation. Then the second DDR layer is deposited on top (10-2000 nm). This preliminary formation of the first layer with specific thickness control enables the overall membrane to achieve thin thickness (100 nm to 5 μm) while maintaining manufacturing reproducibility through the systematic two-layer approach.
Solution Approach 2:
The invention controls the thickness parameters of each layer independently - first layer thickness (50-2000 nm) and second layer thickness (10-2000 nm) - allowing precise adjustment of the overall membrane thickness (100 nm to 5 μm). By optimizing these parameters, the membrane achieves both reduced thickness for improved CO2 separation and high manufacturing reproducibility.
3Reliability
If a single-layer DDR membrane is manufactured, then the structure is simple, but the separation performance and reproducibility are insufficient
Solution Approach 1:
The membrane is segmented into two functional layers with distinct compositions - the first layer contains CHA and DDR structures providing structural foundation and nucleation sites, while the second layer contains primarily DDR structure providing the separation function. This segmentation enhances separation performance and reproducibility while maintaining reasonable structural complexity.
Solution Approach 2:
The CHA-DDR composite structure combines two different zeolite crystal structures in a layered configuration. The CHA phase in the first layer acts as a template and structural support, while the DDR phase in both layers provides the separation functionality, creating a composite material with superior performance compared to single-layer DDR membranes.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The CHA-DDR type zeolite membrane exhibits excellent carbon dioxide separation performance with high purity and improved industrial applicability due to its thin thickness and reproducible manufacturing method, enhancing the separation efficiency of mixed gases and biogas upgrading.
Implementation Method 1
CHA-DDR type zeolite membrane having a high permeance and thin thickness
Implementation Method 2
zeolites are alumina-silica crystal molecular sieves in which tetrahedrons of SiO4 and AlO4− are combined
Implementation Method 3
manufactured using a novel method involving hydrothermal synthesis with specific precursor solutions and calcination processes
Implementation Method 4
zeolites are alumina-silica crystal molecular sieves in which tetrahedrons of SiO4 and AlO4− are combined in a geometric shape to have a regular three-dimensional framework structure
Implementation Method 5
manufactured using a novel method involving hydrothermal synthesis with specific precursor solutions and calcination processes
Implementation Method 6
calcination processes
Data Source
AI summary
The present disclosure may provide a CHA-DDR type zeolite membrane including: a first layer including a CHA structure and a DDR structure; and a second layer which is provided on the first layer and includes a DDR structure, wherein the CHA-DDR type zeolite membrane is in the form of a film having a thickness of 100 nm to 5 μm, including a CHA structure and a DDR structure.