Mixed-Phase Zeolite Membrane for Acid-Resistant Separation
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Solution Overview
Problem
Zeolite separation membranes with high separation performance and acid resistance for practical use have not been easily achievable, as existing membranes like MOR and MFI have limitations in flux and separation coefficient, and complex two-layer structures with high temperature processes do not consistently deliver improved separation performance.
Innovation Solution
A zeolite membrane with a mixed layer of MOR and MFI, grown uniformly from both the surface and deep inside, forming a laminate structure with specific X-ray diffraction patterns, achieving high separation coefficients and acid resistance, and a component separation method using this membrane for efficient separation of organic components from mixed solutions containing water and organic acids.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If MOR zeolite membrane is used for separation, then acid resistance is improved, but permeation flux and water permeability are low
Solution Approach 1:
The patent combines MOR and MFI zeolites into a mixed-phase membrane structure where MOR provides acid resistance and MFI provides high permeation flux. This merging of two different zeolite types allows the membrane to simultaneously achieve both acid resistance and high productivity that neither zeolite can provide alone.
2Productivity
If MFI zeolite membrane is used for separation, then permeation flux and water permeability are improved, but separation coefficient and acid resistance are low
Solution Approach 1:
The patent combines MOR and MFI zeolites into a mixed-phase membrane structure where MOR provides acid resistance and MFI provides high permeation flux. This merging of two different zeolite types allows the membrane to simultaneously achieve both acid resistance and high productivity that neither zeolite can provide alone.
3Manufacturing precision
If two-stage hydrothermal synthesis is used to create two-layer structure, then membrane structure is formed, but process complexity and temperature requirements increase
Solution Approach 1:
The patent merges the formation of MOR and MFI zeolite layers into a single hydrothermal synthesis process, eliminating the need for two-stage synthesis and high-temperature template removal. This single-step approach reduces process complexity while maintaining the desired membrane structure.
Solution Approach 2:
The patent changes the synthesis parameters to enable simultaneous formation of MOR and MFI phases in one hydrothermal treatment, avoiding the need for separate synthesis stages and subsequent high-temperature processing.
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 zeolite membrane achieves high permeation flux and separation coefficients, maintaining performance and acid resistance over time, effectively separating organic components from mixed solutions, including those with organic acids, with a simplified synthesis process compared to previous methods.
Implementation Method 1
A membrane made of zeolite has a characteristic of selectively transmitting molecules according to the size or the shape of molecules, and accordingly, such a membrane is widely used as a molecule sieve.
Implementation Method 2
which has a separation coefficient of at least 500 as measured in pervaporation of a mixed solution containing 10 wt % of water and 90 wt % of isopropyl alcohol
Data Source
AI summary
A zeolite membrane excellent in separation performance and having an acid resistance, and a separation membrane employing the zeolite membrane are provided. A zeolite membrane comprising a layer wherein at least two different types of zeolite crystals are present in mixed state, wherein at least two types of the above at least two different types of zeolite crystals are detectable by an X-ray pattern obtained by X-ray diffraction under the conditions that (A) the output of X-ray is 1.2 kW, (B) an X-ray bulb of copper (Cu) is employed, and (C) the wavelength of X-ray is 1.54058 A. As an alternative, the zeolite membrane comprising a first layer containing zeolite crystals and a second layer containing different type of zeolite crystals from the zeolite crystals of the first layer, wherein the first layer and the second layer constitute a laminate structure, and the thickness of the laminate structure is at most 20 pm.