Fabrication of multi-layer composite hollow fiber membranes for gas separation

Using multilayer composite hollow fiber membranes consisting of a sealing layer (silicone rubber), a selective layer (poly(4-vinylpyridine)), and a support substrate (polysulfone), we have determined the key parameters for fabricating high-performance multilayer hollow fiber composite membranes for gas separation. Surface roughness and surface porosity of the support substrate play two crucial roles in successful membrane fabrication. Substrates with smooth surfaces tend to reduce defects in the selective layer to yield composite membranes of better separation performance. Substrates with a high surface porosity can enhance the permeance of composite membranes. However, SEM micrographs show that, when preparing an asymmetric microporous membrane substrate using a phase-inversion process, the higher the surface porosity, the greater the surface roughness. How to optimize and compromise the effect of both factors with respect to permselectivity is a critical issue for the selection of support substrates to fabricate high-performance multilayer composite membranes. For a highly permeable support substrate, pre-wetting shows no significant improvement in membrane performance. Composite hollow fiber membranes made from a composition of silicone rubber/0.1–0.5 wt% poly(4-vinylpyridine)/25 wt% polysulfone show impressive separation performance. Gas permeances of around 100 GPU for H₂, 40 GPU for CO₂, and 8 GPU for O₂ with selectivities of around 100 for H₂/N₂, 50 for CO₂/CH₄, and 7 for O₂/N₂ were obtained.     

Fabrication of Matrimid/polyethersulfone dual-layer hollow fiber membranes for gas separation

We have developed almost defect-free Matrimid/polyethersulfone (PES) dual-layer hollow fibers with an ultra-thin outer layer of about 10 × 10⁻⁶ m (10 μm), studied the effects of spinneret and coagulant temperatures and dope flow rates on membrane morphology and separation performance, and highlighted the process similarities and differences between single-layer and dual-layer hollow fiber fabrications. The compositions of the outer and inner layer dopes were 26.2/58.8/15.0 (in wt.%) Matrimid/NMP/methanol and 36/51.2/12.8 (in wt.%) PES/NMP/ethanol, respectively. It is found that 25 °C for both spinneret and coagulant is a better condition, and the fibers thus spun exhibit an O₂/N₂ selectivity of 6.26 which is within the 87% of the intrinsic value and a calculated apparent dense-layer thickness of about 2886 × 10⁻¹⁰ m (2886 Å). These dual-layer membranes also have impressive CO₂/CH₄ selectivity of around 40 in mixed gas tests. The scanning electron microscopy (SEM) studies show that low coagulant temperatures produce dual-layer hollow fibers with an overall thicker thickness and tighter interfacial structure which may result in a higher substructure resistance and decrease the permeance and selectivity simultaneously. The elemental analysis of the interface skins confirms that a faster inter-layer diffusion occurs when the fibers are spun at higher spinneret temperatures. Experimental results also reveal that the separation performance of dual-layer hollow fiber membranes is extremely sensitive to the outer layer dope flow rate, and the inner layer dope flow rate also has some influence. SEM pictures indicate that the macrovoid formation in dual-layer asymmetric hollow fiber membranes is quite similar to that in single-layer ones. It appears that macrovoids observed in this study likely start from local stress imbalance and weak points.     

The fabrication of hollow fiber membranes with double-layer mixed-matrix materials for gas separation

The concept of fabricating hollow fibers with double-layer mixed-matrix materials using the same polymeric matrix has been demonstrated for gas separation. Polyethersulfone (PES)–beta zeolite/PES–Al₂O₃ dual-layer mixed-matrix hollow fiber membranes with enhanced separation performance have been fabricated. This study presents an innovative approach of utilizing low cost PES and Al₂O₃ to replace expensive polyimides as the supporting medium for dual-layer mixed-matrix hollow fibers and eliminating interlayer de-lamination problems. The incorporations of 20 wt% beta zeolite in the outer selective layer and 60 wt% Al₂O₃ in the inner layer coupled with spinning at high elongational draw ratios yield membranes with an O₂/N₂ selectivity of 6.89. The presence of Al₂O₃ particles enables the membrane to retain its porous substructure morphology in the course of annealing above the glass transition temperature of PES. Moreover, spinning at high elongational draw ratios results in the re-distribution of Al₂O₃ particles towards both edges of the inner layer. Not only do the permeance and selectivity of the fibers increase, but also greater mechanical properties and lower degree of shrinkages are obtained. Therefore, the combination of PES–beta zeolite and PES–Al₂O₃ nanoparticles with a reasonable draw ratio may be another promising approach to produce hollow fibers with double-layer mixed-matrix materials.     

Impact of operating pressure on the permeance of hollow fiber gas separation membranes

Asymmetric and slightly pressure dependent permeation properties of commercial air separation hollow fibers have been observed – phenomena that have not been mentioned in the literature before. In bore-side feed the permeance of oxygen, nitrogen and helium slightly increases with pressure while in shell-side feed the permeance decreases with pressure. At a feed pressure of 12.8 bar_a the permeance in bore-side feed is about 10–15% higher than in shell-side feed mode. Interestingly, the effect was more or less similar for different gases and different fibers. The results suggest that mechanical stress induced by the pressure difference across the membrane affects the permeability of the skin layer.     

Simulation of binary gas separation in hollow fiber asymmetric membranes by orthogonal collocation

Modeling of hollow fiber asymmetric membrane modules can provide useful guidelines to achieve desirable separations of gas mixtures. In this work the performance of a countercurrent flow separator was analyzed through a parametric study of the most important system variables as functions of basic design and operational parameters. Results refer to CO₂–N₂ separation from power station flue gases as a typical, potential process. The appropriate model equations were solved by orthogonal collocation to approximate differential equations, and to solve the resulting system of non-linear algebraic equations by the Brown method. This technique compared to other applied computational procedures minimized the computational time and effort and improved solution stability. This is very important if the pressure and concentration profiles along the permeator, both in the residue and the permeate streams, need to be determined. These profiles influence strongly the permeator performance and, under certain conditions such as moderate and high feed pressure, they may result in lower than expected permeate purity. The simulation results also indicate that the role of the basic design parameters may be of equal if not higher importance to membrane selectivity. Thus industrial permeator performance, as it is expressed by stage cut and permeate purity, is not very sensitive to membrane permselectivity beyond a modest value of 40–50, especially at moderate and high (15–20 bar) feed pressures. A desirable gas separation may then be achievable with a reasonably permeable, albeit not very selective membrane, provided that design and operating variables are selected appropriately.     

Bromine recovery with hollow fiber gas membranes

Gas membranes supported by microporous hollow fibers have been used to concentrate bromine from a variety of brines similar to seawater. The bromine transport is governed by diffusion in the brine, and hence is almost independent of membrane properties except the surface area per volume. In some cases, this type of membrane can be an alternative to packed towers, simultaneously carrying out both absorption and stripping.     

The effects of spinneret dimension and hollow fiber dimension on gas separation performance of ultra-thin defect-free Torlon hollow fiber membranes

A defect-free as-spun hollow fiber membrane with an ultra-thin dense-selective layer is the most desirable configuration in gas separation because it may potentially eliminate post-treatments such as silicone rubber costing, simplify membrane manufacture, and reduce production costs. However, the formation of defect-free as-spun hollow fiber membranes with an ultra-thin dense-selective layer is an extremely challenging task because of the complexity of phase inversion process during the hollow fiber fabrication and the trade-off between the formation of an ultra-thin dense-selective layer and the generation of defects. We have for the first time successfully produced defect-free as-spun Torlon^® hollow fiber membranes with an ultra-thin dense layer of around 540 Å from only a one polymer/one solvent binary system at reasonable take-up speeds of 10–50 m/min. The best O₂/N₂ permselectivity achieved is much higher than the intrinsic value of Torlon^® dense films. This is also a pioneering work systematically studying the effects of spinneret dimension and hollow fiber dimension on gas separation performance. Several interesting and important phenomena have been discovered and never been reported: (1) as the spinneret dimension increases, a higher elongation draw ratio is required to produce defect-free hollow fiber membranes; (2) the bigger the spinneret dimension, the higher the selectivity; (3) the bigger the spinneret dimension, the thinner the dense-selective layer. Mechanisms to explain the above observation have been elaborated. The keys to produce hollow fiber with enhanced permselectivity are to (1) remove die swell effects, (2) achieve finer monodisperse interstitial chain space at the dense-selective layer by an optimal draw ratio, and (3) control membrane formation by varying spinneret dimension.     

Superior gas separation performance of dual-layer hollow fiber membranes with an ultrathin dense-selective layer

A concept demonstration has been made to simultaneously enhance both O₂ and CO₂ gas permeance and O₂/N₂ and CO₂/CH₄ selectivity via intelligently decoupling the effects of elongational and shear rates on dense-selective layer and optimizing spinning conditions in dual-layer hollow fiber fabrication. The dual-layer polyethersulfone hollow fiber membranes developed in this work exhibit an O₂/N₂ selectivity of 6.96 and an O₂ permeance of 4.79 GPU which corresponds to an ultrathin dense-selective layer of 918 Å at room temperature. These hollow fibers also show an impressive CO₂/CH₄ selectivity of 49.8 in the mixed gas system considering the intrinsic value of only 32 for polyethersulfone dense films. To our best knowledge, this is the first time to achieve such a high CO₂/CH₄ selectivity without incorporating any material modification. The above gas separation performance demonstrates that the optimization of dual-layer spinning conditions with balanced elongational and shear rates is an effective approach to produce superior hollow fiber membranes for oxygen enrichment and natural gas separation.     

Polyimide hollow fiber gas separation membranes: preparation and the suppression of plasticization in propane/propylene environments

Asymmetric hollow fiber membranes were prepared using the polyimide Matrimid^® 5218. The fibers had an effective top layer thickness of 0.3–0.4 μm. The fibers were used in propane and propylene permeation experiments. Whereas the propane permeance remained more or less constant, the propylene permeance increased with feed pressure greater than 1 bar. This indicated that propylene plasticized the membrane material.The fibers were given different heat-treatments in order to investigate the possibilities to suppress the propylene plasticization. This treatment also reduced the permeance considerably, the effect being more pronounced the more intense the heat-treatment was. This was in agreement with scanning electron microscopy studies, which revealed that densification of the fibers occurred due to the heat-treatments. Most important, relatively mild heat-treatments already appeared to be effective in suppressing the propylene plasticization. Since these heat-treated fibers still readily dissolved it is concluded that the plasticization suppression was not due to crosslinking, but to an annealing effect. Due to thermal curing (annealing) at temperatures below the T_g aromatic polyimides tend to form charge transfer complexes, which restrict the polymer chain mobility. Presence of these complexes seems to be responsible for suppression of propylene plasticization.     

Composite hollow fiber membranes for CO2 capture

Composite hollow fibers membranes were prepared by coating poly(phenylene oxide) (PPO) and polysulfone (PSf) hollow fibers with high molecular polyvinylamine (PVAm). Two procedures of coating hollow fibers outside and respective inside were investigated with respect to intrinsic PVAm solution properties and hollow fibers geometry and material.The influence of operating mode (sweep or vacuum) on the performances of membranes was investigated. Vacuum operating mode gave better results than using sweep because part of the sweep gas permeated into feed and induced an extra resistance to the most permeable gas the CO₂. The composite PVAm/PSf HF membranes having a 0.7–1.5 μm PVAm selective layer, showed CO₂/N₂ selectivity between 100 and 230. The selectivity was attributed to the CO₂ facilitated transport imposed by PVAm selective layer. The CO₂ permeance changed from 0.006 to 0.022 m³(STP)/(m² bar h) in direct correlation with CO₂ permeance and separation mechanism of the individual porous supports used for membrane fabrication. The multilayer PVAm/PPO membrane using as support PPO hollow fibers with a 40 nm PPO dense skin layer, surprisingly presented an increase in selectivity with the increase in CO₂ partial pressure. This trend was opposite to the facilitated transport characteristic behaviour of PVAm/porous PSf. This indicated that PVAm/PPO membrane represents a new membrane, with new properties and a hybrid mechanism, extremely stable at high pressure ratios. The CO₂/N₂ selectivity ranged between 20 and 500 and the CO₂ permeance from 0.11 to 2.3 m³(STP)/(m² bar h) depending on the operating conditions.For both PVAm/PSf and PVAm/PPO membranes, the CO₂ permeance was similar with the CO₂ permeance of uncoated hollow fiber supports, confirming that the CO₂ diffusion rate limiting step resides in the properties of the relatively thick support, not at the level of 1.2 μm thin and water swollen PVAm selective layer. A dynamic transfer of the CO₂ diffusion rate limiting step between PVAm top layer and PPO support was observed by changing the feed relative humidity (RH%). The CO₂ diffusion rate was controlled by the PPO support when using humid feed. At low feed humidity the 1.2 μm PVAm top layer becomes the CO₂ diffusion rate limiting step.     

ZIF-8 based polysulfone hollow fiber membranes for natural gas purification

Mixed matrix membranes (MMMs) have received worldwide attention for natural gas purification due to their superior performance in terms of permeability and selectivity. The zeolitic imidazole framework-8 (ZIF-8) blended polysulfone (PSf) membranes have been fabricated for natural gas purification. ZIF-8 was selected due to its low cost, remarkable thermal and chemical stabilities, and tunable microporous structure. The neat PSf hollow fiber membrane and mixed matrix hollow fiber membranes incorporated with the various ZIF-8 loadings up to 1.25% were fabricated. The prepared membranes were evaluated using field emission scanning electron microscopy (FESEM), thermogravimetric analysis (TGA), differential scanning calorimetry (DSC), Fourier transform infrared spectroscopy (FTIR), atomic force microscopy (AFM), and gas separation performance. The low loading of ZIF-8 nanoparticles to the MMM improved thermal stability and glass transition temperature and yielded low surface roughness. MMMs were tested using pure gases with a significant improvement of 36% in CO₂ permeability and 28% in CO₂/CH₄ selectivity compared to the neat membrane. However, the high ZIF-8 loading reduced the separation performances. Moreover, CO₂/CH₄ selectivity decreased at elevated pressure (8 and 10 bar) due to CO₂-induced plasticization. Previously, the incorporation of ZIF-8 particles has primarily been subjected to the fabrication of flat sheet membranes, whereas this work focused on hollow fiber membranes which are rarely investigated. Hence, the promising results obtained at low feed pressure in this study demonstrated the potential of ZIF-8 based hollow fiber membrane for natural gas purification.     

Effect of fiber variation on the performance of cross-flow hollow fiber gas separation modules

A quantitative analysis of the effects of variable fiber properties on the performance of a cross-flow hollow fiber gas separation module is presented. The effects of variations in size, permeance, and selectivity are considered. Fiber variability is detrimental to performance. The recovery and flow rate of an enriched retentate stream decrease as variability increases. Some fibers may actually stop producing product as purity increases. Additionally, performance is poorer if the permeate from all fibers is not well mixed. The results of this work can be used to determine quality control guidelines for fiber manufacture and evaluate process enhancements.     

The rheology of Torlon solutions and its role in the formation of ultra-thin defect-free Torlon hollow fiber membranes for gas separation

Fundamental understanding of the material science and rheological engineering to fabricate Torlon^® 4000T-MV and 4000TF hollow fiber membranes with an ultra-thin and defect-free dense-selective layer for gas separation has been revealed. We have firstly investigated the rheology of Torlon^® 4000T-MV and 4000TF dope solutions, and then determined the effect of temperature-correlated shear and elongational viscosities on the formation of Torlon^® fibers for gas separation. Interestingly, Torlon^® 4000T-MV and 4000TF possess different rheological characteristics: the elongational viscosity of Torlon^® 4000T-MV/NMP solution shows strain thinning, while Torlon^® 4000TF/NMP solution shows strain hardening. The balanced viscoelastic properties of dope solutions, which are strongly dependent on the spinning temperature, have been found to be crucial for the formation of a defect-free dense layer. The optimum rheological properties to fabricate Torlon^® 4000T-MV/NMP hollow fibers appear at about 48–50 °C, and the resultant fibers have an O₂/N₂ selectivity of 8.37 and an apparent dense layer thickness of 781 Å. By comparison, the best Torlon^® 4000TF fibers were spun at 24 °C with an O₂/N₂ selectivity of 8.96 and a dense layer of 1116 Å. The CO₂/CH₄ selectivity of the above two Torlon^® variants is 47 and 53.5, respectively.     

Conductive diamond hollow fiber membranes

Boron-doped diamond hollow fiber membrane (BDD–HFM) was fabricated as a novel type of porous conductive diamond. BDD–HFM was obtained by deposition of BDD polycrystalline film onto a quartz filter substrate consisting of quartz fibers, followed by etching of the substrate in HF/HNO₃ aqueous solution. Cross-sectional scanning electron microscope (SEM) observation showed the inner diameter and wall thickness of the BDD hollow fibers were in the range of 0.4–2 and 0.2–2 μm, respectively. The BDD–HFM electrode exhibited a relatively large double-layer capacitance (ca. 13 F g⁻¹) in 0.1 M H₂SO₄. Electrochemical AC impedance properties were simulated using an equivalent circuit model containing a transmission line model, which indicated characteristics of a porous electrode material.     

The ageing phenomenon of polyethersulphone hollow fibre membranes for gas separation and their characteristics

We have studied the ageing behaviour of PES/NMP (polyethersulphone/N-methyl pyrrolidone) hollow fibres for gas separation that were prepared from 35% and 37% dope. The effect of ageing on hollow fibres spun from low and high shear rate (103 vs. 862 s⁻¹) has also been investigated, in terms of their transport properties (permeation flux and separation performance), thermal, mechanical and tensile properties. Hollow fibres in this study were aged for around four months in ambient air at room temperature prior to testing.In general, the gas permeation flux drops steeply during the 40 days following fabrication and levels off thereafter. The O₂/N₂ selectivity decreases slightly over time. Hollow fibres spun with high shear rate seem to age faster than those spun with low shear rate. The gas fluxes of both membranes were found to follow a log–log relationship with ageing time. For almost all the gases used in this study, the gas flux decay rate, calculated from the slope of the log–log plot of gas flux vs. ageing, is higher for membranes spun with high shear rate. The effect of shear rate on ageing is less significant for smaller gas molecules that travel faster such as He and H₂. No significant effect of ageing on gas selectivity was observed. Experimental results also indicate that the storage modulus and loss modulus of the hollow fibres increase with ageing. Hollow fibres spun with high shear rates give a slightly higher increase in these moduli than those spun at low shear rates. Surprisingly, tangent δ (energy dissipation) and glass transitional temperature are not sensitive to ageing. We also found that the tensile yield strength and Young's modulus of the hollow fibres increase slightly with ageing. The hollow fibre membranes spun at high shear rates also show a higher increment in tensile yield stress. However, the change in Young's modulus due to ageing was similar for fibres spun with high and low shear rates.     

Characterization of substructure resistance in asymmetric gas separation membranes

Gas permeation through a typical state-of-the-art membrane can be described by defining three morphological features: namely skin thickness, skin integrity, and substructure resistance. Traditional gas permeation measurements tend to characterize skin thickness and skin integrity, but not substructure resistance. This presents a serious obstacle to the optimization of advanced hollow fiber membranes, since as skin thicknesses are reduced, substructure resistance becomes an increasingly significant contribution to the overall permeation rate. This paper illustrates how substructure resistance can affect permeation properties and demonstrates a new technique for characterizing this frequently important morphological feature. The technique involves applying a constant transmembrane pressure while varying the average gas pressure within the membrane. Thus, the mean free path of gas molecules permeating through the substructure can be altered while maintaining a constant driving force for permeation. Such experiments characterize the magnitude of the substructure resistance, as well as provide insight into the governing transport mechanism. These constant driving force/variable pressure permeation measurements can estimate the average pressure or mean free path at the transition where substructure resistance becomes negligible. This can then be used to compare the morphological features of different membranes. This technique is demonstrated on well-defined coated ceramic membranes, asymmetric polymeric flat sheet membranes, and asymmetric polymeric hollow fiber membranes.     

Oxygen selective ceramic hollow fiber membranes

Oxygen ion conducting Ba_0.5Sr_0.5Co_0.8Fe_0.2O_3−δ hollow fiber membranes with o.d. 1.15 mm and i.d. 0.71 mm were fabricated using a sequence of extrusion, gelation, coating and sintering steps. The starting ceramic powder was synthesized by combined EDTA–citrate complexing followed by thermal treatment at 900 °C. The powder was then dispersed in a polymer solution, and extruded through a spinerette. After gelation, an additional thin coating of the ceramic powder was applied on the fiber, and sintering was carried out at 1190 °C to obtain the final ceramic membrane. The fibers were characterized by SEM, and tested for air separation at ambient pressure and at temperatures between 700 and 950 °C. The maximum oxygen flux measured was 5.1 mL/min/cm² at 950 °C.     

New approach to chemical modification of PIM-1 for gas separation membranes

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Cobalt-doped silica membranes for gas separation

Cobalt-doped silica membranes were synthesized using tetraethyl orthosilicate-derived sol mixed with cobalt nitrate hexahydrate. The cobalt-doped silica structural characterization showed the formation of crystalline Co₃O₄ and silanol groups upon calcination. The metal oxide phase was sequentially reduced at high temperature in rich hydrogen atmosphere resulting in the production of high quality membranes. The cobalt concentration was almost constant throughout the film depth, though the silica to cobalt ratio changed from 33:1 at the surface to 7:1 at the interface with the alumina layer. It is possible that cobalt has more affinity to alumina, thus forming CoOAl₂O₃. The He/N₂ selectivities reached 350 and 570 at 160 °C for dry and 100 °C wet gas testing, respectively. Subsequent exposure to water vapour, the membranes was regenerated under dry gas condition and He/N₂ selectivities significantly improved to 1100. The permeation of gases generally followed a temperature dependency flux or activated transport, with best helium permeation and activation energy results of 9.5 × 10⁻⁸ mol m⁻² s⁻¹ Pa⁻¹ and 15 kJ mol⁻¹. Exposure of the membranes to water vapour led to a reduction in the permeation of nitrogen, attributed to water adsorption and structural changes of the silica matrix. However, the overall integrity of the cobalt-doped silica membrane was retained, given an indication that cobalt was able to counteract to some extent the effect of water on the silica matrix. These results show the potential for metal doping to create membranes suited for industrial gas separation.