Dense ceramic catalytic membranes and membrane reactors for energy and environmental applications

Catalytic membrane reactors which carry out separation and reaction in a single unit are expected to be a promising approach to achieve green and sustainable chemistry with less energy consumption and lower pollution. This article presents a review of the recent progress of dense ceramic catalytic membranes and membrane reactors, and their potential applications in energy and environmental areas. A basic knowledge of catalytic membranes and membrane reactors is first introduced briefly, followed by a short discussion on the membrane materials including their structures, composition and strategies for material development. The configuration of catalytic membranes, the design of membrane reaction processes and the high temperature sealing are also discussed. The performance of catalytic membrane reactors for energy and environmental applications are summarized and typical catalytic membrane reaction processes are presented and discussed. Finally, current challenges and difficulties related to the industrialization of dense ceramic membrane reactors are addressed and possible future research is also outlined.     

Porous ceramic membranes for catalytic reactors — overview and new ideas

The membrane reactor (MR) concept, combining in the same unit a conversion effect (catalyst) and a separation effect (membrane), already showed various potential benefits (increased reaction rate, selectivity and yield) for a range of reactions involving the membrane as extractor, distributor or contactor. Due to the generally severe conditions of heterogeneous catalysis, most MR applications use inorganic membranes, which can be dense or porous, inert or catalytically active. After a rapid overview of the working concepts of MRs, the main types of porous ceramic membranes, which have been developed for MR applications, are reported and discussed (characteristics and limitations). Starting from these general basis, our objective is to put recent developments into focus, with a special emphasis on porous composite infiltrated membranes and related synthesis methods. Some new ideas currently explored in our group, such as the ‘chemical valve membrane’ concept and the interest of nanophase materials for oxygen transport, will be also developed. An attempt in addressing the future developments of porous membranes for MRs will be finally proposed.     

INORGANIC POROUS MEMBRANES FOR LIQUID PHASE SEPARATION

Porous ceramic membranes are reviewed with reference to liquid phase separation. Methods for preparing porous ceramic membranes are summarized after a brief introduction to membranes and membrane processes. In the section on liquid phase separation, membrane materials are summarized from the viewpoint of pore size limits, since the pore sizes of porous membranes play an important role in determining separation performance. Various types of metal oxides and composite oxides have been developed by the sol-gel process; typical materials are Al₂O₃, TiO₂, SiO₂, ZrO₂, and composite oxides. The sol-gel process has a great advantage in terms of pore-size controllability over a wide range, from 0.5 ～ several ten nm, and therefore, is suitable for preparing membranes for use in liquid phase separation. Applications of inorganic membranes are reviewed in terms of water treatment, separation of nonaqueous systems, and photocatalysis.     

Hydrogen Permeation Properties of Perovskite-type BaCe_(0.9)Mn_(0.1)O_(3-δ)Dense Ceramic Membrane

In recent years, mixed-conducting oxides, in which both protonic and electronic charge carriers exist, have received increasing attentions1. Ceramic membranes made of such materials are semipermeable to hydrogen at elevated temperatures. In the early 1980s, Iwahara et al. first reported protonic conduction in SrCeO3-based materials2. Later, BaCeO3 system was extensively studied because of its higher conductivities. However, the electronic conductivity of rare earth doped-BaCeO3 ceramic…     

Inorganic Membranes for Hydrogen Separation

Hydrogen, one of the most promising energy carriers for the future, is currently produced mainly by natural gas reforming or coal gasification, where mixtures containing H₂, CO₂ and contaminants like CO, H₂S and CH₄ are obtained. Among other methods, membrane technology has received special attention due to its potential efficiency for hydrogen separation, simplicity of operation, low energy consumption, and because it is environmentally friendly. For this application, the inorganic membranes can be essentially divided into five main families: metallic and proton conducting (dense phases), and silica, zeolite and carbon molecular sieve (porous solids). Over the past 20 years, palladium-based membranes have been the most studied and implemented at industrial level; however, recent advances in other membrane types have received a great deal of attention. This article critically reviews more than 520 publications, highlighting the latest research developments on inorganic membranes for the recovery and purification of hydrogen, with emphasis on their structural characteristics, synthesis, commercial application, drawbacks and challenges. Furthermore, a large compilation of data is provided in Supplementary Material divided according to membrane type.     

Sputtered,electroless, and rolled palladium–ceramic membranes

Three techniques were used to produce palladium–ceramic (Pd–ceramic) composite membranes for hydrogen separation and production. They are sputtering, electroless deposition and rolling of thin Pd alloy films over ceramic porous tubes.After studying and developing the three coating techniques, an extensive testing and characterizing work was carried out on these thin film composite membranes. The results show that in the sputtered (0.5–5 μm) and electroless (2.5–20 μm) composite membranes, the thermal cycling of the hydrogenated metallic layer produces membrane failures. Such failures are characterized by crack formation and metal film peeling. This fact has been explained by an evaluation of the shear stresses at the metal–ceramic interface due to the differential elongation between the palladium (Pd) coating and the ceramic support under thermal cycling and hydrogen loading. The rolled membranes (50–70 μm), however, because of the particular coating solution, have shown a complete hydrogen selectivity and good chemical and physical stability in long-term tests.     

Recent advances in application of the graphene-based membrane for water purification

Graphene is an atomic layer thick carbon-based material with unique two-dimensional architecture and extraordinary physiochemical, optical, electrical, and mechanical properties. Graphene and its derivatives show significant promises for the development of nanoporous ultrathin filtration membranes capable of molecular separation properties. Graphene-based nanofiltration membranes featuring distinct laminar structures can offer various novel mass-transport phenomena for purifying water, energy storage and separation, gas separation, and proton conductors. The latest developments in water purification techniques through graphene-based membranes including engineering, design, and fabrication of diverse graphene, graphene-oxide, and graphene-composite membranes are provided here in relation to their application paradigm for purifying water. The critical views on pollutant removal mechanisms for water purification along with optimization measures are specially highlighted. In addition, the challenges, shortcomings, and future prospects are pointed out. The green and large-scale synthesis technology of graphene coupling with advanced membrane fabrication techniques can promote these state-of-the-art nanofiltration membranes for a wide range of applications.     

Preparation and Chiral Selectivity of BSA-Modified Ceramic Membrane

Chirality plays an important role in the function of biological processes. For isolating only the desired enantiomer, various methods have been developed, such as high performance liquid chromatography and capillary electrophoresis1. But with these method…     

Inorganic membranes and solid state sciences

The latest developments in inorganic membranes are closely related to recent advances in solid state science. Sol–gel processing, plasma-enhanced chemical vapor deposition and hydrothermal synthesis are methods that can be used for inorganic membrane preparation. Innovative concepts from material science (templating effect, nanophase materials, growing of continuous zeolite layers, hybrid organic–inorganic materials) have been applied by our group to the preparation of inorganic membrane materials. Sol–gel-derived nanophase ceramic membranes are presented with current applications in nanofiltration and catalytic membrane reactors. Silica membranes with an ordered porosity, due to liquid crystal phase templating effect, are described with potential application in pervaporation. Defect-free and thermally stable zeolite membranes can be obtained through an original synthesis method, in which zeolite crystals are grown inside the pores of a support. Hybrid organic–inorganic materials with permselective properties for gas separation and facilitated transport of solutes in liquid media, have been successfully adapted to membrane applications. Potential membrane developments offered by CVD deposition techniques are also illustrated through several examples related to the preparation of purely inorganic and hybrid organic–inorganic membrane materials.     

NaA型分子筛膜的合成及分离性能的研究

在自制的片状多孔陶瓷载体上,通过多次原位水热晶化合成出ＮａＡ型分子筛膜,通过扫描电子显微镜观测,发现在某些区域,小颗粒的ＮａＡ型分子筛以非常紧密的形式畸晶孪生在一起,其致密度远好于由分子筛晶粒松散无规律堆积而形成的膜排列经类膜生长形式可能是获得取致密无缺陷型分子筛膜的一种途径,单组分及双组分气体渗透测试结果表明,在所合成的分子筛膜上,晶粒间隙孔可能是主要的膜扩散通道,可凝聚气体异丁烷因发生毛细管凝     

Microfiltration process by inorganic membranes for clarification of TongBi liquor

Membrane separation is an alternative separation technology to the conventional method of filtration. Hence, it has attracted use in the purification and concentration of Chinese Herbal Medicine Extracts (CHMEs). The purpose of this work was to study the process of microfiltration of Tongbi liquor (TBL), a popular Chinese herbal drink, using ceramic membranes. Zirconium oxide and aluminum oxide membranes with pore mean sizes of 0.2 μm and 0.05 μm, respectively, are used for comparisons in terms of flux, transmittance of the ingredients, physical-chemical parameters, removal of macromolecular materials and fouling resistance. The results show that 0.2 μm zirconium oxide membrane is more suitable. The stable permeate flux reaches 135 L·h(-1)·m(-2), the cumulative transmittance of the indicator is 65.53%. Macromolecular materials, such as starch, protein, tannin, pectin and total solids were largely eliminated in retentate after filtration using 0.2 μm ZrO2 ceramic membrane, resulting in clearer TBL. Moreover, this work also reveals that continuous ultrasound could strengthen membrane process that the permeate flux increases significantly. This work demonstrates that the purification of CHME with ceramic membranes is possible and yielded excellent results.     

Protein fractionation and detection for metalloproteomics: challenges and approaches

At least one third of all proteins are thought to require a metal ion co-factor for their function. Recognition of the importance of metals in biological systems and major advances in analytical instrumentation and technology have led to the emergence of the new research area of metalloproteomics in recent years. Despite this progress, the experimental determination of in-vivo metal cofactors has remained challenging, because this requires elucidation of protein interactions with non-covalently bound metal ions. This critical review highlights current methodological approaches, focusing, in particular, on issues relating to the fractionation and separation of the metalloproteome, including recent experience with metalloproteomics for marine cyanobacteria in our laboratory. Metalloproteomics promises to deliver novel insights into fundamental biological processes in the future, but it is clear that further methodological advances are necessary to exploit the full potential of this emerging research area.     

High-flux ceramic membranes with a nanomesh of metal oxide nanofibers

Traditional ceramic separation membranes, which are fabricated by applying colloidal suspensions of metal hydroxides to porous supports, tend to suffer from pinholes and cracks that seriously affect their quality. Other intrinsic problems for these membranes include dramatic losses of flux when the pore sizes are reduced to enhance selectivity and dead-end pores that make no contribution to filtration. In this work, we propose a new strategy for addressing these problems by constructing a hierarchically structured separation layer on a porous substrate using large titanate nanofibers and smaller boehmite nanofibers. The nanofibers are able to divide large voids into smaller ones without forming dead-end pores and with the minimum reduction of the total void volume. The separation layer of nanofibers has a porosity of over 70% of its volume, whereas the separation layer in conventional ceramic membranes has a porosity below 36% and inevitably includes dead-end pores that make no contribution to the flux. This radical change in membrane texture greatly enhances membrane performance. The resulting membranes were able to filter out 95.3% of 60-nm particles from a 0.01 wt % latex while maintaining a relatively high flux of between 800 and 1000 L/m2.h, under a low driving pressure (20 kPa). Such flow rates are orders of magnitude greater than those of conventional membranes with equal selectivity. Moreover, the flux was stable at approximately 800 L/m2.h with a selectivity of more than 95%, even after six repeated runs of filtration and calcination. Use of different supports, either porous glass or porous alumina, had no substantial effect on the performance of the membranes; thus, it is possible to construct the membranes from a variety of supports without compromising functionality. The Darcy equation satisfactorily describes the correlation between the filtration flux and the structural parameters of the new membranes. The assembly of nanofiber meshes to combine high flux with excellent selectivity is an exciting new direction in membrane fabrication.     

Nano/subnano-tuning of porous ceramic membranes for molecular separation

In sol–gel processing, porous ceramic membranes can be prepared by sol-coating porous substrates and drying for gelling, followed by a firing process. Ceramic membranes prepared by sol–gel processing can be categorized into amorphous materials such as silica, and crystalline materials such as alumina and titania. Amorphous silica networks, which can be prepared by the polymeric sol route, have ultra-microporous pores that allow small molecules such as helium and hydrogen to permeate. On the other hand, crystalline materials, which are mostly prepared by the colloidal sol route, have nano-sized pores in the range of one to several nanometers. In this article, sol–gel derived SiO₂ and TiO₂ membranes with controlled pore sizes in the range of sub-nano to nanometers will be reviewed with respect to membrane preparation and to their application in the separation of the gas and liquid phases. Ceramic membranes with high performance can be obtained by precise control of membrane structures (pore size, pore size distribution, thickness, pore shape, etc.) and membrane materials (SiO₂, TiO₂, composite oxide, hybrid materials, etc.). Nano/subnano-tuning of porous ceramic membranes is quite important for the improvement of membrane permeability and selectivity.     

Preparation of Zeolite X Membranes on Porous Ceramic Substrates with Zeolite Seeds

Zeolite X membranes were investigated by in-situ hydrothermal synthesis on porous ceramic tubes precoated with zeolite X seeds or precursor amorphous aluminosilicate, and porous α-Al2O3 ceramic tubes with a pore size of 50 200 nm were employed as supports. Zeolite X crystals were synthesized by the classic method and mixed into deionized water as a slurry with a concentration of 0.2 0.5wt%, having a range of crystal sizes from 0.2 to 2μm. Crystal seeds were pressed into the pores near the inner surface of the ceramic tubes, and crystallization took place at 95℃ for 24-96 h. It was also investigated that Boehmite sol added with zeolite X seeds was precoated on ceramic supports to form a layer of γ-Al2O3 by heating, and hydrothermal crystallization could then take place to prepare the zeolite membranes on the composite ceramic tubes. The crystal species were characterized by XRD, and the morphology of the supports subjected to crystallization was characterized by SEM. The composite zeolite membranes have zeolitic top-layers with a thickness of 10-25 μm, and zeolite crystals can be intruded into pores of the supports as deeply as 100μm. The experimental results indicate that the precoating of zeolitic seeds on supports is beneficial to crystallization by shortening the synthesis time and improving the membrane strength. The resulting zeolite X membrane shows permselectivity to tri-n-butylamine((C4H9)3N) over perfluro-tributyl-amine ((C4Fg)3N), and a permeance ratio of 57 for ((C4Hg)3N to (C4F9)3N could be reached at 350℃. Permeances of BZ, EB and TIPB through the zeolite membrane were also measured and were found to slightly increase with temperature.     

Preparation of silica–alumina composite membranes for hydrogen separation by multi-step pore modifications

In the present paper, a silica–alumina composite membrane for hydrogen separation was prepared within an α-alumina support by the multi-step pore modification. The α-alumina support has an asymmetric structure composed of a thin dense skin layer and a thick coarse layer and the average pore size of its skin layer is 80 nm. The composite membrane layer was formed in the vicinity of the interphase between the two layers of the support by two consecutive steps; namely, in situ silica sol–gel reaction and soaking and vapor deposition. In order to enhance the hydrogen selectivity, palladium (Pd) particles were impregnated in the final step utilizing Pd-acetate as a Pd precursor. Although both silica and Pd induced the surface diffusion, Pd was more effective for selective hydrogen adsorption than silica. This multi-step method produced a porous membrane with moderate hydrogen selectivity and satisfactory hydrogen permeance at high temperature and at high transmembrane pressure. The separation factor of hydrogen relative to nitrogen was maintained at about 10 even when the transmembrane pressure was as high as 110 kPa, and the hydrogen permeance was still much higher than that of non-porous polymeric membranes. In addition, the microstructural distributions of Si and Pd within the intermediate membrane layer were examined by a scanning electron microscopy (SEM) and an energy dispersive X-ray analysis (EDX)     

Theory of pressure-driven transport of neutral solutes and ions in porous ceramic nanofiltration membranes

Hindered transport theory and homogeneous electro-transport theory are used to calculate the limiting, high volume flux, rejection of, respectively, neutral solutes and binary electrolytes by granular porous nanofiltration membranes. For ceramic membranes prepared from metal oxides it is proposed that the membrane structural and charge parameters entering into the theory, namely the effective pore size and membrane charge density, can be estimated from independent measurements: the pore radius from the measured hydraulic radius using a model of sintered granular membranes and the effective membrane charge density from the hydraulic radius and the electrophoretic mobility measurements on the ceramic powder used to prepare the membrane. The electro-transport theory adopted here is valid when the membrane surface charge density is low enough and the pore radius is small enough for there to be strong electrical double layer overlap in the pores. Within this approximation the filtration streaming potential is also derived for binary electrolytes.     

Pervaporation with chitosan membranes II. Blend membranes of chitosan and polyacrylic acid and comparison of homogeneous and composite membrane based on polyelectrolyte complexes of chitosan and polyacrylic acid for the separation of ethanol-water mixtures

Three different types of blend membranes based on chitosan and polyacrylic acid were prepared from homogeneous polymer solution and their performance on the pervaporation separation of water-ethanol mixtures was investigated. It was found that all membranes are highly water-selective. The temperature dependence of membrane permselectivity for the feed solutions of higher water content (>30 wt%) was unusual in that both permeability and separation factor increased with increase in temperature. This phenomenon might be explained from the aspect of activation energy and suggested that the sorption contribution to activation energy of permeation should not always be ignored when strong interaction occurs in the pervaporation membrane system.A comparison of pervaporation performance between composite and homogeneous membranes was also studied. Typical pervaporation results at 30°C for a 95 wt% ethanol aqueous solution were: for the homogeneous membrane, permeation flux = 33 g/m² h, separation factor = 2216; and for the composite membrane, permeation flux = 132 g/m² h, separation factor = 1008. A transport model consisting of dense layer and porous substrate in series was developed to describe the effect of porous substrate on pervaporation performance.     

Evolution of pore size distribution and average pore size of porous ceramic membranes during modification by counter-diffusion chemical vapor deposition

The modification of porous ceramic membranes by counter-diffusion chemical vapor deposition (CVD) is studied theoretically and experimentally. Numerical simulations of the evolution of the membrane permeance, average pore size and pore size distribution as a function of extent of modification are presented and compared with experimetal data. It is found that the change of the average pore size of the membranes after modification strongly depends on the initial pore size distribution of the membrane, CVD reaction kinetics and characterization method. Experimental data suggest that CVD of zirconia (and yttria) inside porous ceramic membranes by reaction of zirconium (and yttrium) chlorides with steam/air at elevated temperatures proceeds by quasi-zero reaction kinetics with respect to the oxidant, typical of non-stoichiometric supply of the reactants from opposite sides of the membrane. Under such conditions, CVD modification may result in a modest increase of the average pore size of coarse-pore ceramic membranes as suggested by numerical calculations and experimental data.