Microwave Synthesis of Supported Molecular Sieve Membranes
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Solution Overview
Problem
The synthesis of molecular sieve membranes faces challenges with temperature gradients and sedimentation during heat transfer, leading to poor product stability and high production costs, limiting their industrial application.
Innovation Solution
A method involving in-situ aging and microwave synthesis, where the support is aged at 25° C. to 70° C. for 10-24 hours and heated to synthesis temperature within 1-10 minutes using microwaves, followed by synthesis at 80° C. to 120° C. for 2-15 minutes, effectively stabilizing the membrane production process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional heat transfer methods are used for molecular sieve membrane synthesis, then the process can be carried out, but temperature gradients and sedimentation occur leading to poor product stability
Solution Approach 1:
The patent replaces conventional thermal conduction heat transfer with microwave radiation heating. The microwave heating system directly irradiates the synthesis mixture, providing uniform volumetric heating that eliminates temperature gradients caused by conductive heat transfer limitations. This substitution of heating mechanism resolves the contradiction between achieving synthesis temperature and maintaining temperature uniformity.
Solution Approach 2:
The patent changes the heating method from conventional thermal conduction to microwave radiation, fundamentally altering the heat transfer parameters. This parameter change enables simultaneous achievement of high synthesis temperature and temperature uniformity, resolving the technical contradiction that plagues conventional methods.
2Productivity
If conventional synthesis methods are used, then molecular sieve membrane can be produced, but synthesis time is long and production efficiency is low
Solution Approach 1:
The patent replaces conventional thermal conduction heating with microwave radiation heating. Microwave heating provides direct volumetric energy input that dramatically accelerates the synthesis reaction rate. This substitution of heating mechanism reduces synthesis time from hours to minutes while maintaining product quality, thereby resolving the contradiction between synthesis time and production efficiency.
Solution Approach 2:
The patent utilizes the dielectric heating effect and rapid phase transition characteristics of microwave radiation to accelerate the synthesis process. The microwave energy induces rapid molecular vibration and collision, facilitating faster reaction kinetics and shorter synthesis times compared to conventional heating methods.
3Device complexity
If in-situ aging-microwave synthesis method is used, then crystal seed coating process is replaced, but product performance shows strong instability within and between batches
Solution Approach 1:
The patent optimizes multiple synthesis parameters including microwave power density, aging time, synthesis temperature, and mixture composition to achieve consistent product performance. By systematically controlling these parameters and establishing optimal process windows, the patent resolves the instability issue while maintaining the simplified in-situ aging approach.
Solution Approach 2:
The patent implements quality control feedback mechanisms to monitor and adjust synthesis parameters in real-time. By monitoring product characteristics during synthesis and making corrective adjustments, the patent ensures consistent product performance across batches while maintaining the simplified production process.
4Loss of energy
If conventional synthesis conditions are used, then synthesis can proceed, but energy consumption and resource consumption are high
Solution Approach 1:
The patent replaces inefficient thermal conduction heating with highly efficient microwave radiation heating. Microwave heating provides direct volumetric energy input with minimal heat loss, significantly reducing overall energy consumption while maintaining or improving synthesis rates. This substitution of heating mechanism resolves the contradiction between energy consumption and synthesis productivity.
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 method significantly improves product pass and top-grade rates, reduces energy and resource consumption, and shortens synthesis time, making large-scale industrial application feasible.
Implementation Method 1
the aging is to make a support in contact with a synthetic liquid at 25° C. to 70° C. for 10 hours to 24 hours
Implementation Method 2
the heating is to raise a temperature of an aged system from an aging temperature to a synthesis temperature within 1 minute to 10 minutes; and the synthesizing is to synthesize at 80° C. to 120° C. for 2 minutes to 15 minutes, wherein the steps of heating and synthesizing are powered by microwaves
Implementation Method 3
a molecular sieve crystal grows on the pre-nuclei through energy supply by microwaves
Data Source
AI summary
A method for synthesizing a supported molecular sieve membrane by microwaves includes the steps of aging, heating and synthesizing. The aging step is to make a support in contact with a synthetic liquid at 25° C. to 70° C. for 10 hours to 24 hours; the heating step is to raise a temperature of an aged system from an aging temperature to a synthesis temperature within 1 minute to 10 minutes; and the synthesizing step is to synthesize at 80° C. to 120° C. for 2 minutes to 15 minutes. The steps of heating and synthesizing are powered by microwaves.