Zeolite Membrane Complex with Tetravalent Element for Polar Molecule Permeability

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Solution Overview

Problem

Zeolite membranes have limited permeability for polar molecules due to their low affinity, and introducing tetravalent elements like silicon into the ALPO-type zeolite membrane framework is challenging, especially when synthesized on a support.

Innovation Solution

A zeolite membrane complex with a specific composition containing aluminum, phosphorus, and a tetravalent element, such as silicon, is formed on a porous support, with a controlled molar ratio of these elements to enhance permeability, using a method involving a precursor solution and hydrothermal synthesis.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If a tetravalent element such as silicon is introduced into the zeolite framework to improve permeability of polar molecules, then permeability of polar molecules is improved, but control of the site of introduction becomes difficult when synthesized on a support

Engineering Contradiction:

Improvepermeability of polar moleculesVSAvoidcontrol of site of introduction

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The patent applies preliminary action by pre-forming ALPO-type zeolite membranes on porous supports before introducing tetravalent elements through ion exchange or framework substitution during or after synthesis. This preliminary membrane formation on supports enables subsequent controlled modification without the difficulties of direct in-situ synthesis, thereby improving permeability while maintaining manufacturing control.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent utilizes parameter changes by adjusting synthesis conditions such as pH, temperature, and composition ratios of aluminum and phosphorus to control the incorporation of tetravalent elements into the zeolite framework. By optimizing these parameters, the patent achieves both improved permeability of polar molecules and controlled site introduction, resolving the technical contradiction.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If ALPO-type zeolite membrane is used, then separation of substances can be achieved, but permeability of polar molecules is limited due to low affinity

Engineering Contradiction:

Improveseparation capabilityVSAvoidpermeability of polar molecules

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent applies composite materials by combining ALPO-type zeolite with tetravalent elements (such as silicon) to create a composite zeolite structure. This composite approach maintains the separation capability of the original ALPO-type zeolite while adding the permeability enhancement from tetravalent element incorporation, thereby resolving the contradiction between reliability and productivity.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent implements local quality by selectively introducing tetravalent elements at specific sites within the zeolite framework, particularly at positions that enhance interaction with polar molecules. This localized modification improves permeability for polar molecules while preserving the overall separation structure and capability of the ALPO-type zeolite membrane.

Inventive Principle:

Principle #3Local quality

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 complex exhibits improved permeability for polar molecules, achieving high selectivity and efficiency in separating substances like water, CO2, and NH3, with a helium to CF4 permeance ratio of at least 500.

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

a substance having high permeability is separated from other substances by allowing the substance with high permeability to permeate through the zeolite membrane complex

Methodology Applied

Scientific EffectPermeation: Permeation

Implementation Method 3

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

Methodology Applied

Scientific EffectAdsorption: Adsorption

Data Source

PatentUS20220047995A1Zeolite membrane complex, method of producing zeolite membrane complex, separator, membrane reactor, and separation method

Publication Date: 2022.02.17 NGK INSULATORS LTD

AI summary

A zeolite membrane complex includes a porous support and a zeolite membrane formed on the support. The zeolite membrane contains Al, P, and a tetravalent element. The composition of the zeolite membrane measured by X-ray photoelectron spectroscopy is such that the molar ratio of the tetravalent element to Al is higher than or equal to 0.01 and lower than or equal to 0.5, the molar ratio of P to Al is higher than or equal to 0.5 and lower than 1.0, and the total molar ratio of P and the tetravalent element to Al is higher than or equal to 0.9 and lower than or equal to 1.3. The zeolite membrane contains a zeolite crystal with an accessible volume higher than or equal to 450 Å3.