Zeolite Membrane Complex Uniformity via Hydrothermal Rotation
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Solution Overview
Problem
Conventional methods for synthesizing long-length zeolite membranes often result in composition variations and defects such as poor membrane formation, heterogeneous phases, and cracks, especially when using stationary hydrothermal synthesis, which complicates the apparatus and increases costs, making it difficult to produce high-quality zeolite membranes with minimal defects.
Innovation Solution
A longitudinal zeolite membrane complex with a support of 50 cm or more, featuring through holes along its length, where the zeolite membrane is uniformly formed with a controlled temperature gradient during hydrothermal synthesis, ensuring consistent composition and minimizing defects by maintaining a temperature gradient of 0.1 to 10°C/m and using a hydrothermal synthesis apparatus that uniformly heats the starting material solution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If stationary hydrothermal synthesis is used for longitudinal zeolite membrane complex, then apparatus complexity is reduced, but membrane composition uniformity deteriorates and defects increase
Solution Approach 1:
The patent applies dynamics by rotating the longitudinal support during hydrothermal synthesis instead of keeping it stationary. This rotation creates dynamic fluid circulation in the starting material solution, ensuring uniform temperature and composition distribution along the entire length of the support, thereby achieving consistent membrane composition without requiring complex heating control systems.
Solution Approach 2:
The patent replaces complex thermal control mechanisms with a simpler mechanical rotation system. Instead of using multiple heating zones and sophisticated temperature control apparatus to maintain uniformity, the invention uses mechanical rotation of the support to achieve uniform exposure of all membrane surfaces to the starting material solution, significantly reducing apparatus complexity while improving composition uniformity.
2Manufacturing precision
If rotation method from Document 1 is used, then membrane composition uniformity improves, but apparatus complexity and cost increase
Solution Approach 1:
The patent applies local quality by rotating only the longitudinal support containing the membrane, while keeping the reaction container and heating system stationary. This localized rotation approach achieves uniform membrane composition without requiring the entire hydrothermal synthesis apparatus to be complex or expensive, as only the support structure needs rotation capability.
3Manufacturing precision
If stirring method from Document 2 is used, then membrane composition uniformity improves, but apparatus complexity and cost increase
Solution Approach 1:
The patent applies inversion by rotating the support structure itself rather than using a separate stirring mechanism to mix the solution. This reverse approach achieves the same effect of uniform composition distribution but with simpler apparatus, as the support rotation naturally circulates the starting material solution without requiring additional stirring blades or motors within the reaction container.
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 approach results in a zeolite membrane complex with reduced defects, consistent composition, and improved membrane quality, enabling efficient gas separation with minimal variation in the main element concentration across the membrane, enhancing its separation performance and durability.
Implementation Method 1
while the heating part heats the starting material solution at a predetermined synthesis temperature in the hydrothermal synthesis, the temperature gradient of the starting material solution between respective positions facing one side and the other side of the support in a longitudinal direction ranges from 0.1 to 10° C./m
Implementation Method 2
forming a zeolite membrane on the support by immersing the support in a starting material solution for zeolite membrane formation and performing hydrothermal synthesis
Data Source
AI summary
A zeolite membrane complex includes a longitudinal support member having at least one through hole extending along its length and a zeolite membrane on an inner peripheral surface of the through hole or over an outer peripheral surface of the support, from one end portion of the support to the other end portion thereof. Among constituent elements of the zeolite membrane except oxygen, an element with the highest percentage is a main element, and when the concentration of the main element is measured at three portions defined by dividing the support into three equal parts in the longitudinal direction, the concentration of the main element gradually decreases from the one end portion toward the other end portion, and the ratio of the concentration of the main element at the other end portion to that at the one end portion is 0.90 or more.