Zeolite Membrane Composite Segmentation for Defect-Free Separation

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Solution Overview

Problem

Conventional zeolite membrane composites face challenges in achieving both high permeability and selectivity due to defects and thickness limitations, with sparse zeolite layers compromising strength and permeation flux.

Innovation Solution

A zeolite membrane composite is developed with a low-density layer covering a porous support, topped by a compact layer having a higher zeolite crystalline phase content and larger particle diameter, produced through seed crystal lamination and hydrothermal synthesis, optimizing the molar ratio of structure-directing agents to enhance layer thickness and selectivity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the zeolite membrane is reduced in thickness to improve permeability, then permeability is improved, but defects are more likely to occur reducing reliability

Engineering Contradiction:

ImprovepermeabilityVSAvoiddefect occurrence

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The zeolite membrane is segmented into multiple layers with different densities: a low-density layer covering the porous support and a compact high-density layer covering the low-density layer. This segmentation allows the membrane to achieve high permeability through the low-density layer while maintaining reliability through the defect-free compact layer, resolving the contradiction between thinning for permeability and preventing defects for reliability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the zeolite membrane are given different local qualities: the low-density layer provides high permeability with larger voids, while the compact layer provides high reliability with dense structure and no defects. This local differentiation allows each layer to optimize for its specific function, achieving both high permeability and high reliability simultaneously.

Inventive Principle:

Principle #3Local quality

2Ease of manufacture

If a sparse zeolite layer is used to reduce manufacturing complexity, then ease of manufacture is improved, but strength and permeation flux deteriorate

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidusage resistance

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The zeolite membrane uses a composite structure combining low-density and compact high-density layers. The low-density layer is easier to form and provides structural coverage, while the compact layer enhances strength and permeation flux. This composite approach maintains ease of manufacture through sequential formation while dramatically improving mechanical strength and permeation performance.

Inventive Principle:

Principle #40Composite materials

3Manufacturing precision

If a compact zeolite membrane with no defects is formed to improve selectivity, then selectivity is improved, but membrane thickness increases reducing permeability

Engineering Contradiction:

ImproveselectivityVSAvoidpermeability

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The membrane is segmented into two functional layers: the low-density layer serves as a thick permeable substrate providing high permeability, while the compact layer serves as a thin selective barrier providing high selectivity. This segmentation allows the system to achieve both high permeability through the thick low-density layer and high selectivity through the thin compact layer, resolving the contradiction between thickness for selectivity and thinness for permeability.

Inventive Principle:

Principle #1Segmentation

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 composite achieves high permeability and selectivity by reducing defects and thickness, allowing efficient separation of gases and liquids, such as CO2 and CH4, with improved durability and permeance ratios.

Implementation Method 1

using the molecular-sieving function of the zeolite in applications such as separation or adsorption of specific molecules

Methodology Applied

Scientific EffectMolecular sieving: Molecular Sieve

Implementation Method 2

hydrothermally synthesizing the seed crystals in a starting material solution

Methodology Applied

Scientific EffectHydrothermal synthesis:

Data Source

PatentUS12151216B2Zeolite membrane composite, method of producing zeolite membrane composite, and separation method

Publication Date: 2024.11.26 NGK INSULATORS LTD

AI summary

A zeolite membrane composite includes a porous support and a zeolite membrane formed on the support. The zeolite membrane includes a low-density layer that covers the support, and a compact layer that covers the low-density layer. The compact layer has a higher content of a zeolite crystalline phase than the low-density layer. By in this way forming the compact layer on the low-density layer that covers the support, the thin compact layer with no defects can be formed more easily than in the case where a compact layer is formed directly on a support.