The objective of this study was to investigate the transport properties and the microstructure of CMS membranes derived from a carbon-rich intrinsically microporous polyimide precursor. CMS membranes were prepared by a heat treatment of the polyimide precursor using a well-defined heating protocol in a horizontal tube furnace up to 1000 °C. A nitrogen purge was kept inside the furnace to remove all the evolved by-products as the precursor started to decompose and carbonize. The microstructures of the carbon molecular sieve membranes (CMSMs) were examined using wide-angle x-ray diffraction, Raman spectra, N2 adsorption and CO2 adsorption. The average interlayer spacing (d002) between the graphite plates was estimated using the data obtained by the WXRD. The average d002 decreased as a result of increasing the pyrolysis temperature; average d002 distances for CMS prepared at 700 and 1000 °C were estimated to be 0.40 to 0.38 nm, respectively. Raman spectra confirmed the progressive structural ordering as heat-treatment temperature increased. A substantial decrease in the intensity of the D band was observed as a function of pyrolysis temperature, indicating a decrease in the disordered structure. Graphitic structure and turbostratic carbon coexist in the as-prepared carbon membranes, of which the microcrystal size La and the stacking height Lc were increasing as a function of pyrolysis temperature. N2 adsorption showed a remarkable increase in the BET surface area as a function of pyrolysis temperature. BET surface areas for the pristine and CMSs prepared at 700 to 900 °C were in the range of 650 to 680 m2/g with a remarkable shift in the pore size distribution toward the ultra- microporous region. CO2 adsorption was used to estimate the surface area for pores with sizes of less than 1 nm. Surface areas were observed to increase from 350 m2/g at 500 °C to 857 m2/g at 800 °C, and then started dropping slightly from 857 to 650 m2/g at 800 to 1000 °C, respectively. This is believed to be caused by pore shrinkage effect being severe after 800 °C, which caused some pores to be hard to spot by the CO2 adsorption technique. The transport properties of the pristine and CMS membranes were tested using pure gases He, H2, N2, CH4, CO2, and O2. From the pristine to SBFDA-DMN-700°C, the selectivity increased significantly, with a massive loss in the permeability except for He and H2. From SBFDA-DMN- 700 °C to 900 °C, a substantial increase in selectivity with a moderate decline in permeability was observed. Beyond 900 °C, the permeability again decreased moderately, but a tremendous increase in the selectivity for N2/CH4, CO2/CH4, and H2/CH4 was observed.

Nitrogen-selective Carbon Molecular Sieve (CMS) membranes were developed for nitrogen/methane separation. Effects of pyrolysis conditions including pyrolysis temperature protocol and pyrolysis atmosphere were studied for Matrimid® and 6FDA:BPDA-DAM precursors. It was revealed that high pyrolysis temperature is essential to achieve attractive nitrogen/methane selectivity due to the subtle size difference between the two gas penetrants. Detailed study on one of the best performing CMS membranes showed that diffusion selection, more specifically, the entropic factor responsible for diffusion selection provides a significant contribution to the high selectivity. The effect of precursor was studied by considering nine carefully selected polymers. The structures and properties of these polymer precursors were compared and correlated with the separation performance of resulting CMS membranes. The translation of intrinsic CMS transport properties into the hollow fiber morphology was also explored. Substructure collapse and asymmetry lost during pyrolysis were observed, which resulted in significant increases of separation layer thickness and decreases in permeance. Vinyltrimethoxy silane (VTMS)-treatment was applied to polymer hollow fiber before pyrolysis to overcome the problem of substructure collapse. The effects of VTMS-treatment on both the substructure and skin layer are discussed.

Efficient propylene and propane separation is a major challenge in the modern chemical industry. With current separation methods being highly energy-intensive, there is a pressing need to find alternative green technology. Membrane separation emerged as a promising candidate for propylene and propane separation. Their small footprint, low cost, reliability, and environmental friendliness give membrane separation systems a competitive edge in the race towards sustainable development. The continuous advancements in material science created avenues for new membrane materials such as carbon molecular sieve (CMS) membranes which exhibit exceptional gas separation performances for challenging applications due to their strong size-sieving capabilities. In this work, a carbon molecular sieve (CMS) membrane derived from a polymer of intrinsic microporosity (TPE-PIM) has been investigated for propylene/propane separation made by pyrolysis at 400, 450, 500, 550, 600, 650, and 700 ºC. TPE-PIM-derived CMS films showed excellent pure and mixed-gas permeability and selectivity, exceeding the upper bound limits for propylene and propane. Observed in this work was the presence of an optimal pyrolysis temperature at 600 ºC, where the film showed the best performance with a permeability of 41.6 Barrer and a selectivity of 197 based on pure-gas measurements but dropping to 34 Barrer and selectivity of 33 under equimolar mixed-gas conditions. Such performance could be attributed to the unique internal structural changes that occurred during the pyrolysis. In addition, propane permeability though the CMS films was slow and required long times to reach steady-state values. Such slow kinetics illustrates the molecular sieving capabilities of CMS membranes for bigger and more condensable gases. Several characterization techniques have been performed on the films to confirm CMS formation and showcase deeper molecular structure insights. X-ray diffraction of all TPE-PIM films showed a broad spectrum at each peak due to the material’s amorphous nature. Diffraction patterns also revealed a gradual peak shift for the (002) plane towards smaller values closer to that of pure graphite. Raman spectra showed the characteristic D and G peaks for carbon films prepared at 500 ºC and above. FTIR analysis was also performed to investigate the potential formation of triazine crosslinks in the thermally treated samples, but no conclusive results were obtained.

Carbon molecular sieve (CMS) membranes represent the most attractive pure component materials to compete against polymer membranes for high performance gas separations. CMS membranes are formed from the thermal decomposition of polymer precursors and can therefore be formed into continuous defect free membranes with excellent gas separation performance. Over the last 20 years, CMS membranes have been produced in a variety of geometries and have a wide range of separation performance applicable to several important gas separations. Though research into CMS membrane formation is quite extensive, the relationship between synthesis factors and separation performance is still not well understood. The goal of this study was to elucidate the effect of two different synthesis factors on the separation performance of CMS membranes to allow more control over separation performance. The foci of this study were to clarify (1) the effect of pyrolysis atmosphere and (2) the effect of polymer precursor composition. Dense flat CMS membranes were synthesized from 6FDA:BPDA-DAM precursor at 550 oC using several pyrolysis atmospheres including vacuum pyrolysis (<0.05 torr), helium and argon flowing at atmospheric pressure, and helium and argon flowing at reduced pressures. The separation performance of CMS membranes produced under different pyrolysis atmospheres suggests that the amount of oxygen available during pyrolysis has a significant affect on the microstructure of membrane. CMS membranes were produced from 6FDA:BPDA(1:1)-DAM and 6FDA:BPDA(1:1)-DAM under identical pyrolysis conditions to determine the utility of polymer precursor composition as an engineering tool to fine-tune the performance of CMS membranes. In a second study utilizing 6FDA-6FpDA and 6FDA-6FmDA precursors, the separation performance of CMS membranes was shown to be dependent on the intrinsic precursor free volume. These studies have shown that two factors to be considered when choosing a polymer precursor are the intrinsic free volume of the polymer and the composition of the by-products evolved during pyrolysis.

Ethylene is the most important organic molecule with regard to production volume. Therefore, the energy spent in its separation processes, based on old-fashioned distillation, takes approx. 33% of total operating costs. Membranes do not require significant thermal energy input; therefore, membrane processes may separate hydrocarbons cheaply and just as reliably as distillation columns. Olefin/paraffin separations are the future targets of commercial membrane applications, provided high-performing materials become available at reasonable prices. This thesis addresses the development of advanced carbon molecular sieve (CMS) membranes derived from intrinsically microporous polymers (PIMs). Chronologically, Chapter 4 of this work reports the evaluation of PIMs as potential ethylene/ethane selective materials, while Chapters 5 to 7 propose PIMs as carbonization precursors. The gravimetric sorption studies conducted in this work regarding both the polymers and their heated-derivatives revealed that this separation is entirely controlled by diffusion differences. The pristine polymers examined in this study presented BET surface areas from 80 to 720 m2g-1. Furthermore, the effect of using bromine-substituted PIM-polyimides elucidated a boost in ethylene permeability, but with a significant drop in selectivity. The hydroxyl functionalization of PIM-polyimides was confirmed as a valuable strategy to increase selectivity. Functionalized PMDA-HSBF is the most selective polyimide of intrinsic microporosity known to date (= 5.1) due to its hydrogen-bonded matrix. In spite of their novelty, pristine PIMs based on the spirobisindane moiety were not tight enough to distinguish between the 0.2 Å difference in diameter of the ethylene/ethane molecules. Therefore, they did not surpass the upper bound limit performance of known polymeric membranes. Nevertheless, the carbons derived from these polymers were excellent ethylene/ethane sieves by virtue of their narrow and tight pore distribution around the 3.6- 4.4 Å range. PIM-based carbons were typically 10 times more permeable than their corresponding low free-volume analogues treated after the weight-loss of the sample reached a plateau. Furthermore, carbons derived from PIM-6FDA-OH and PIM-6FDA at 800 ºC were as ethylene separating efficient as their lower free-volume counterparts. The pore sintering mechanism that takes place above 600 ºC during the carbonization procedure of these films reduced the entropic freedom of the molecules, as was observed from separation factors of up to 25 under pure-gas conditions and 2 bar of pressure— The best performing CMS membranes reported to date for ethylene/ethane separation. The mixed-gas separation of 1:1 binary ethylene/ethane mixtures revealed a significant decrease of the pure-gas measurements due to a carbon matrix dilation effect. This localized ultramicroporous dilation caused the ethane permeation rate to increase monotonically as the pressure rose to realistic operating values. Nevertheless, the CMS obtained from PIM-6FDA and PIM-6FDA-OH surpassed any diffusion-controlled polymer or carbon that has been reported to date.

Current membrane technology, based on polymeric materials, is subject to a limiting tradeoff between productivity (permeability) and efficiency (selectivity). Other materials with better gas separation performance exist, such as zeolites and carbon molecular sieves, but the physical characteristics of these materials inhibit industrial scale membrane preparation. This research focuses on the application of hybrid membrane technology, which has shown the ability to combine the advantageous properties of these materials, to a system comprised of carbon molecular sieves dispersed in the upper bound polymer 6FDA-6FpDA. Hybrid membranes require effective mass transfer across the interface between the two phases. This work shows the sensitivity of the component materials to processing conditions and the importance of consistency in gas separation membrane production. In particular, milling the sieves to reduce the size and using chemical linkage agents to bond to the polymer have potential to alter the separation performance of the respective materials. Analysis of multiple factors in this work provides important information regarding the source of unexpected properties in the hybrid membranes. Hybrid membrane testing in this work shows a need for active control of particle agglomerates within the dope prior to casting for effective membrane production. Continual sonication during the preparation of the casting dope was able to prevent the excessive agglomerates present in earlier trials. Further reduction of stresses generated during the casting process was also necessary to produce membranes with enhanced selectivity. Annealing the hybrid films above the polymer Tg appears to repair the interfacial morphology and produce effective membranes. The application of this process to enhance the gas separation performance of 6FDA-6FpDA represents the first known report of successful selectivity improvement in an upper bound polymer using the hybrid membrane approach.

A new innovative polymer pyrolysis method was proposed for creation of attractive carbon molecular sieve (CMS) membranes. Oxygen exposure at ppm levels during pyrolysis was hypothesized and demonstrated to make slit-like CMS structures more selective and less permeable, which I contrary to ones expectation. Indeed prior to this work, any exposure to oxygen was expected to result in removal of carbon mass and increase in permeability. The results of this study indicated that the separation performance and CMS structure may be optimized for various gas separations by careful tuning of the oxygen level. This finding represents a breakthrough in the field of CMS membranes. Simple replacement of pyrolysis atmospheres from vacuum to inert can enable scale-up. The deviation in CMS membrane performance was significantly reduced once oxygen levels were carefully monitored and controlled. The method was shown to be effective and repeatable not only with dense films but also with asymmetric hollow fiber membranes. As a result, this work led the development of the "inert" pyrolysis method which has overcome the challenges faced with previously studied pyrolysis method to prepare attractive CMS membranes. The effect of oxygen exposure during inert pyrolysis was evaluated by a series of well-controlled experiments using homogeneous CMS dense films. Results indicated that the oxygen "doping" process on selective pores is likely governed by equilibrium limited reaction rather than (i) an external or (ii) internal transport or (iii) kinetically limited reaction. This significant finding was validated with two polyimide precursors: synthesized 6FDA/BPDA-DAM and commercial Matrimid®, which implies a possibility of the "inert" pyrolysis method application extending towards various precursors. The investigation was further extended to prepare CMS fibers. Despite the challenge of two different morphologies between homogeneous films and asymmetric hollow fibers, the "inert" pyrolysis method was successfully adapted and shown that separation performance can be tuned by changing oxygen level in inert pyrolysis atmosphere. Moreover, resulting CMS fibers were shown to be industrially viable. Under the operating condition of ~80 atm high pressure 50/50 CO2/CH4 mixed gas feed, the high separation performance of CMS fibers was shown to be maintained. In addition, elevated permeate pressures of ~20 atm did effect the theoretically predicted separation factor. While high humidity exposures (80%RH) resulted in reduced permeance, high selectivity was sustained in the fibers. Recommendations to overcome such negative effects as well as future investigations to help CMS membranes to be commercialized are provided.

The current work focused on defining the material science options to fabricate novel, high performing ethylene/ethane (C₂H₄/C₂H₆) separation carbon molecular sieve (CMS) dense film membranes. Three polymer precursors: Matrimid®, 6FDA-DAM and 6FDA:BPDA-DAM were used as precursors to the CMS membranes. CMS performances were tailored by way of tuning pyrolysis conditions such as the pyrolysis temperature, heating rate, pyrolysis atmosphere etc. The CMS dense film membranes showed attractive C₂H₄/C₂H₆ separation performance far exceeding the polymeric membrane performances. Semi-quantitative diffusion size pore distributions were constructed by studying the transport performance of a range of different penetrant gases as molecular sized probes of the CMS pore structure. This, in conjunction with separation performance data, provided critical insights into the structure-performance relationships of the CMS materials. The effects of testing conditions, i.e. the testing temperature, pressure and feed composition on C₂H₄/C₂H₆ separation performance of CMS dense films were also analyzed. These studies were useful not just in predicting the membrane behavior from a practical stand-point, but also in a fundamental understanding of the nature of CMS membrane separation. The study helped clarify why CMS membranes outperform polymeric membrane performance, as well as allowed comparison between CMS derived from different precursors and processing conditions. The effects on C₂H₄/C₂H₆ separation in the presence of binary gas mixture were also assessed to get a more realistic measure of the CMS performance resulting from competition and bulk flow effects. The current work thus establishes a framework for guiding research ultimately aimed at providing a convenient, potentially scalable hollow fiber membrane formation technology for C₂H₄/C₂H₆ separation

Olefin/paraffin separation is a large potential market for membrane applications. Carbon molecular sieve membranes (CMS) are promising for this application due to the intrinsically high separation performance and the viability for practical scale-up. Intrinsically high separation performance of CMS membranes for olefin/paraffin separations was demonstrated. The translation of intrinsic CMS transport properties into the hollow fiber configuration is considered in detail. Substructure collapse of asymmetric hollow fibers was found during Matrimidﾮ CMS hollow fiber formation. To overcome the permeance loss due to the increased separation layer thickness, 6FDA-DAM and 6FDA/BPDA-DAM polyimides with higher rigidity were employed as alternative precursors, and significant improvement has been achieved. Besides the macroscopic morphology control of asymmetric hollow fibers, the micro-structure was tuned by optimizing pyrolysis temperature protocol and pyrolysis atmosphere. In addition, unexpected physical aging was observed in CMS membranes, which is analogous to the aging phenomenon in glassy polymers. For performance evaluation, multiple "proof-of-concept" tests validated the viability of CMS membranes under realistic conditions. The scope of this work was expanded from binary ethylene/ethane and propylene/propane separations for the debottlenecking purpose to mixed carbon number hydrocarbon processing. CMS membranes were found to be olefins-selective over corresponding paraffins; moreover, CMS membranes are able to effectively fractionate the complex cracked gas stream in a preferable way. Reconfiguration of the hydrocarbon processing in ethylene plants is possible based on the unique CMS membranes.