Porous Support-CHA Zeolite Membrane for Gas Separation
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Solution Overview
Problem
Current zeolite membranes for gas separation are limited by high costs per unit area and require enhanced permeation performance to achieve practical applications, necessitating both high throughput and separation efficiency.
Innovation Solution
A porous support-zeolite membrane composite is developed, where the zeolite penetrates into the porous support with a controlled depth of 5.0 µm or less, utilizing a CHA zeolite structure with a SiO2/Al2O3 molar ratio of 8 or more, and an inorganic porous support like silica or alumina, to enhance permeation and separation performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If zeolite membrane is used for gas separation, then separation performance is improved, but cost per unit area increases
Solution Approach 1:
The invention utilizes a porous support structure with controlled pore size and distribution to enhance gas permeation. The porous support allows selective passage of gas molecules based on size and affinity, achieving high separation performance while reducing the required membrane area and overall cost
Solution Approach 2:
The invention creates a composite membrane system combining zeolite coating on porous support. This composite structure integrates the molecular sieve properties of zeolite with the mechanical strength and permeability of porous support materials, achieving both high separation performance and cost-effectiveness
2Ease of manufacture
If membrane area is reduced to lower cost, then cost per unit area decreases, but permeation performance may be compromised
Solution Approach 1:
The porous support provides high porosity and controlled pore architecture that enhances gas transport efficiency. The three-dimensional porous network allows multiple permeation pathways, maintaining high throughput even with reduced membrane area
Solution Approach 2:
The invention transitions from traditional two-dimensional membrane planning to three-dimensional porous structure utilization. The porous support creates internal surface area and multiple transport dimensions, effectively increasing permeation capacity without proportionally increasing membrane footprint
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
This configuration achieves high permeance for gases like carbon dioxide and hydrogen, with a high separation coefficient, enabling efficient gas separation and concentration while reducing membrane area and cost.
Implementation Method 1
separation between carbon dioxide and methane is demanded and as the zeolite membrane enabling successful separation therebetween, DDR (Patent Document 4), SAPO-34 (Non-Patent Document 1) and SSZ-13 (Non-Patent Document 2), each utilizing the molecular sieve function of zeolite, are known as a high-performance membrane
Implementation Method 2
separate by permeation a high-permeability component from the mixture or concentrate a low-permeability component by permeation and separation of a high-permeability component
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
An object of the present invention is to provide a porous support-zeolite membrane composite ensuring that at the time of separation or concentration with a zeolite membrane, both sufficient throughput and high separation performance are achieved in practice. The present invention relates to a porous support-zeolite membrane composite having a porous support and a zeolite membrane formed on the porous support, wherein part of the zeolite membrane penetrates into the inside of the porous support and the distance from the surface of the porous support to the inside into which the zeolite film penetrates is 5.0 µm or less on average.