Thesis (Ph. D.)--Chemical and Biomolecular Engineering, Georgia Institute of Technology, 2008. / Koros, William J., Committee Chair ; Breedveld, Victor, Committee Member ; Jones, Christopher W., Committee Member ; Kumar, Satish, Committee Member ; Nair, Sankar, Committee Member.

Thesis (Ph. D.)--Chemical and Biomolecular Engineering, Georgia Institute of Technology, 2007. / Teja, Amyn, Committee Member ; Koros, William, Committee Chair ; Jones, Christopher, Committee Member ; Nair, Sankar, Committee Member ; Kumar, Satish, Committee Member.

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.

This research aimed to unite virtues of intrinsically microporous polyimides (PIM-PIs) and thermally treated polymers to develop advanced high-performance membranes with not only high permeability and high selectivity, but mechanical resilience, thermal and chemical stability, and plasticization resistance. Recent research showed that thermal treatment of polymers below or above their degradation temperatures is a potential avenue for improving gas transport properties. Thermally rearranged (TR), thermally crosslinked, or carbon molecular sieve (CMS) membranes have demonstrated promising results in addressing some pressing challenges of gas separation membranes such as chemical stability and plasticization resistance. However, the thermal treatment of PIM-PIs is scarcely studied, and its effect on gas transport properties still remains vague. This Ph.D. work started by investigating the solid-state conversion of PIM-PIs into heterocyclic ring systems upon heat treatment. The PIM-PIs containing functional hydroxyl- and cyano-groups were thermally treated to derive two types of cyclisation systems – conventional polybenzoxazole (PBO) and novel isoindoloquinazolinedione (IQD). Compared to the PIM-PI derived PBO, the novel solid-state conversion of intrinsically microporous cyanoimides into IQD favorably enhanced ultramicropores with up to 80% increase in gas permeability without an expense of gas-pair selectivity. Furthermore, by studying the thermal treatment of non-functionalized and functionalized 6FDA-based polymers a long-neglected contribution of fluorine to the formation of micropores was revealed. It was concluded that the heat treatment induced a continuous fluorine release at 450 °C – crosslinking polymer chains and increasing free volume accessible for gas transport. Finally, for the first time, a hydroxyl-functionalized PIM-PI, 6FDA-HTB, was heat treated by stepwise temperature increase from below, to near and above its degradation temperature to form TR, intermediate and early-stage CMS membranes. This study provided valuable insights on the correlation between the ultra- and micropore development and gas transport properties in PIM-PIs as a function of treatment temperature. Compared to the precursor, the intermediate stage membranes possessed 20-30 times higher CO2 permeability with equivalent CO2/CH4 selectivity. Also, intermediate and early-stage carbon derivatives of 6FDA-HTB exhibited an outstanding 1:1 CO2/CH4 mixed-gas separation results well transcending the 2018 mixed-gas upper bound line. These results deemed further investigation of intermediate stage membranes attractive.

This dissertation focuses on the synthesis and characterization of high performance polymers, especially polyimides, polybenzoxazoles and polybenzimidazoles for gas separation applications. An abundance of monomers and novel polymers were synthesized and fabricated into membranes. Thermally rearranged polybenzoxazoles and their precursor polyimides were systematically studied with regard to size of pendant functional groups, thermal rearrangement conversion, and relationship of backbone structure/gas transport properties. 3,3'-Diamino-4,4'-dihydroxybiphenyl was synthesized using an economical route. Meta and para oriented polyimides with different ortho-functionality were synthesized and these polymers were thermally rearranged into polybenzoxazoles. The polar hydroxyl functional groups on the polyimide backbone diminished the meta/para isomer effect of the permeability coefficients of the polymers and only a small difference between meta- and para-oriented polyhydroxyimides in permeability coefficients was observed. The TR polybenzoxazoles derived from meta/para-oriented isomeric polyimides with ortho functionality had similar gas separation properties, especially for CO2/CH4 separation, and it is hypothesized that this is due to a lack of intersegmental mobility distinction between the two isomeric TR polymers. The TR polymers derived from the polyimides with acetate ortho-functional groups had significantly better gas separation properties than ones derived from the precursor with hydroxyl ortho-functional groups. Polybenzimidazoles were also investigated for use as gas separation membranes. Polybenzimidazoles are some of the most thermally stable polymers. However, commercial polybenzimidazoles do not have good solubility in common solvents. The solubility issue was solved by incorporating sulfonyl linkages into the polybenzimidazole backbone using a 3,3',4,4'-tetraaminodiphenylsulfone (TADPS) monomer. 3,3',4,4'-Tetraaminodiphenylsulfone was synthesized by a novel route with higher overall yield and less steps than the traditional synthetic method. The TADPS based polybenzimidazoles also demonstrated better thermal stability than commercial polybenzimidazole. The meta/para oriented isomer effect on gas transport properties is discussed. TADPS-based polybenzimidazoles exhibited H2/CO2 gas separation properties near or surpassing the upper bound with H2 permeabilities from 3.6 to 5.7 Barrer and selectivities from 10.1 to 32.2 at 35 °C. / Ph. D.

A series of hybrid inorganic-organic composites were fabricated from a functionalized fluorinated polyimide and tetraethoxysilane (TEOS), tetramethoxysilane, methyltrimethoxysilane (MTMOS), and phenyltrimethoxy-silane (PTMOS) employing the sol-gel process. Polyimides were synthesized from 4,4'-hexafluoroisopropylidene dianiline (6FpDA) and 4,4'-hexafluoroisopropyl-idenediphthalic anhydride (6FDA) utilizing a solution imidization technique. The hybrid materials were synthesized by in-situ sol-gel processing of the aforementioned alkoxides and a fully imidized polyimide that was functionalized with 3-aminopropyltriethoxysilane. The gas permeability, diffusivity, and selectivity were evaluated for He, O2, N2, CH4, and CO2, while the physical properties of these hybrid materials were evaluated using several analytical techniques. The results from this study revealed that gas transport and physical properties were dependent on the type of alkoxide employed in the hybrid inorganic-organic material. Gas permeability was observed to increase with increasing gas penetrant size for MTMOS and PTMOS based hybrids, while TEOS based hybrids decreased gas permeability at all compositions. In general, MTMOS based hybrid materials had the largest increases in permeability, which was attributed to an increase in free volume. The TEOS based hybrid materials had the largest decreases in permeability, while PTMOS based hybrid materials had performance in between these alkoxides. Decreased permeability for the TEOS based hybrids was attributed to the formation of lower permeable material at a particle interface and coupled with increasing tortuosity. Results of PALS studies suggested that there was an increase in free volume and pore size for MTMOS based hybrids, while both TEOS and PTMOS based hybrids had decreases in both average pore size and free volume. The temperature dependence of permeation, diffusivity, and sorption were evaluated from 35oC to 125oC. These results suggested that there was a decrease in solubility for all hybrids employed in this study. Furthermore, increases in permeability for the MTMOS based hybrids were created by increased penetrant diffusion. Physical property studies revealed that the type of inorganic material incorporated into the hybrid influences the degree of swelling, bulk density, Tg, and thermal stability. Hybrid materials were also created employing 3,5-diaminobenzoic acid (DABA) in the synthesis of modified 6FDA-6FpDA polyimides in order to evaluate how improvements in inorganic and polymer compatibility influenced the gas transport properties. From this separate study, it was found that increases in both permeability and selectivity were possible. The mechanism attributed to this simultaneous increase in permeability and selectivity was the formation of a more permeable and selective interphase at the interface of an inorganic particle and the polymer matrix. In addition to these studies, 6FDA-6FpDA polyimide molecular weights were changed from 19.3K to 35.3K to probe its role on gas transport and physical properties. These studies revealed that permeability, diffusivity, and solubility increased with increasing molecular weight, while density decreased with increasing molecular weight. These results suggest that there is an increase in free volume with increasing 6FDA-6FpDA polyimide molecular weight. / Ph. D.

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.

Natural gas feeds often contain contaminants such as CO₂, H₂S, H₂O, and small hydrocarbons. Carbon dioxide is a major contaminant reducing the heating value of the gas and causing pipeline corrosion, so CO₂ level should be lowered to below 2% to meet the United States pipeline specifications. Membrane separation technology can be advantageous over cryogenic distillation and amine adsorption in terms of cost and efficiency. The key hurdle to overcome in polymeric membrane separation technology is improvement in selectivity, productivity, and durability without introducing significant additional cost. The ultimate goal of this study is to analyze effects due to polymerization conditions and imidization methods on properties of 1,3-propanediol monoesterified crosslinkable polyimide (PDMC). Hillock, Omole, Ward, and Ma did work on PDMC synthesis; however, variability of polymer properties remains a challenge that must be overcome for industrial implementation of PDMC material. First, reaction temperature and reaction time of polymerization prior to imidization were considered as key conditions to affect molecular weight, crosslinkability and transport properties of polymer. Batches with controlled reaction temperature and time were prepared, and properties of each dense film were measured and optimized in terms of permeability, selectivity, and plasticization suppression. Second, imidization methods for PDMC were also studied. There are mainly two kinds of Imidization: chemical Imidization and thermal Imidization. Surprisingly, thermally imidized PDMC showed 70% higher permeability than chemically imidized samples with minimal acrifice in selectivity. At high reaction temperature during the thermal imidization, transamidation can occur. It is believed that the transamidation led to more randomized sequence distribution in the thermally imidized samples. We thus hypothesize that the higher permeability of the thermally imidized PDMC results from greater uniformity of the sequence distribution, as compared to the chemically imidized sample that does not experience high temperature during imidization. XRD, DSC, DMA, and permeation instruments checked and supported this hypothesis. FTIR, TGA, and NMR ruled out the possibility of an alternate hypothesis related to side reaction. Finally, effects of aggressive feed conditions on both chemically imidized PDMC and thermally imidized PDMC dense film were examined. The aggressive feed conditions include high CO₂ partial pressure, operating temperatures, and exposure to high feed pressure. Testing aggressive feed conditions for dense film should be pursued before pursuing hollow fiber applications, to decouple effects on the basic material from those on the more complex asymmetric morphology. This study enables understanding of the disparity between various previous researchers’ selectivity and permeability values. The work shows clearly that polymerization conditions and imidization methods must be specified and controlled to achieve consistently desirable polymer properties. In addition, for batch scale-up and development to a hollow fiber, this fundamental study should enable production of high molecular weight PDMC with good fiber spinnability and defect-free structure.

Mixed matrix membranes that comprise domains of organic and inorganic components are investigated in this research. Such materials effectively circumvent the polymeric 'upper bound trade-off curve' and show properties highly attractive for industrial gas separations. Nevertheless, lack of intrinsic compatibility between the organic polymers and inorganic fillers poses the biggest challenge to successful fabrication of mixed matrix membranes. Consequently, control of the nanoscale interface between the sieve and polymer has been the key technical challenge to the implementation of composite membrane materials. The overarching goal of this research was to devise and explore approaches to enhance the performance of mixed matrix membranes by properly tailoring the sieve/polymer interface. In an effort to pursue the aforementioned objective, three approaches were developed and inspected: (i) use of silane coupling agents, (ii) hydrophobizing of sieve surface through alcohol etherification reactions, and (iii) a two-step modification sequence involving the use of a Grignard reagent. A comparison was drawn to evaluate these methodologies and the most effective strategy (Grignard treatment) was selected and further investigated. Successful formulation and characterization of mixed matrix membranes constituting zeolite 4A modified via the Grignard treatment are described in detail. Membranes with impressive improvements in gas separation efficiency and mechanical properties were demonstrated. The basis for the improvements in polymer/sieve compatibility enabled by this specific process were proposed and investigated. A key aspect of the present study was illuminating the detailed chemical mechanisms involved in the Grignard modification. Systematic characterization and carefully designed experiments revealed that the formation of distinctive surface structures is essentially a heterogeneous nucleation process, where Mg(OH)2 crystals grow from the nuclei previously extracted from zeolites. In addition to the main work, discovery of sonication-induced dealumination of zeolites was made during the systematic exploration of Grignard chemistry. The new procedure employing sonication can potentially be applied to prepare zeolites with a variety of Si/Al ratios under relatively mild conditions. The last part of this thesis focused on development of a technique to generalize the highly specific Grignard treatment to inorganic materials other than zeolite 4A. This work delivered composite membranes with improved interfacial adhesion. Moreover, research revealed the effect of surface nuclei density on the ultimate morphology of deposited nanostructures and how different surface morphologies influence polymer/filler interaction in composite membranes. Methods were devised to tailor the morphologies of such structures in order to optimize adhesion enhancement. The acquired results demonstrated the potential of extending this modification process to a broad domain of materials and render it a general methodology for interfacial adhesion promotion.

Abstract NEW SYNTHETIC STRATEGIES FOR IMPROVED GAS SEPARATION BY NANOPOROUS ORGANIC POLYMERS Suha S. Altarawneh, Ph.D. The emission of carbon dioxide (CO2) from fossil fuel combustion is a major cause of climate change. Therefore, the efficient separation of CO2 from mixtures of gases such as flue gas and impure sources of CH4 (e.g. natural gas and landfill gas) is an essential step in meeting the ever increasing demands on natural gas and creating a cleaner environment. Carbon capture and storage technology (CCS) is one of the methods employed for gas separation using chemisorption and/or physisorption processes. Several materials such as porous polymers and amine solutions have been used as gas adsorbents. However, the amount of energy required for the adsorbent regeneration is one of the main concerns that needs to be addressed. In this regard, porous organic polymers (POPs) with defined porosity and preferential binding affinity for CO2 over N2 and CH4 are some of the most attractive materials that could fulfill the above requirement and are also applicable for use in gas storage and separation. Suitable POPs that can be used for gas storage applications need to have high porosity and mechanical stability under high pressure conditions (~100 bar). Alternatively, the most effective POPs in gas separation are those that have preferential binding affinity for CO2 over other gases present at low pressure settings. In all cases, the chemical nature of POPs and their textural properties are key parameters, however, the modest surface area of most POPs limits their efficiency. With the above considerations in mind, the aim of our research is to develop benzimidazole–linked polymers (BILPs) that have variable porosity levels and chemical functionality to enhance gas separation (CO2/CH4, CO2/N2). We have established new synthetic routes that utilize polycondensation reactions between aryl-aldehydes and aryl-o-diamine building units to construct new BILPs with improved gas separation properties. Our strategy targeted structural and textural modifications of BILPs. We used longer linkers (building units) to improve porosity; however, the flexible linkers offered only low porosity due to network interpenetration. To overcome this challenge, a more controlled network growth rate was assessed by adjusting imine-bond formation rates through different acid loading. The acid, HCl, was used to catalyze imine-bond formation. The new resulting acid-catalyzed BILPs have shown an improved porosity up to 92% compared to the non-catalyzed BILPs. We also used the “rational ligand design” approach to introduce new functionalities into BILPs (-OR) to alter the hydrophobic nature of their pores. In this regard, we have illustrated the applicability of this strategy to BILPs containing flexible aryl-o-diamine linkers. The bulky alkoxy groups were incorporated into the aryl-aldehyde building unit prior to polymerization. The resulting polymers have proven that the presence of the bulky pendant alkoxy-chains plays a significant role during the polymerization process which allows for increased control over network formation, and in turn, porosity. Sorption measurements, selectivity, and heats of adsorption data have confirmed the positive impact of the alkoxy-groups and shown that varying the pendant groups is a promising method for designing highly porous BILPs. In addition to pore functionalization with alkoxy-chains, we used pi-conjugated and N-rich building units to prepare new BILPs that have semiconducting properties in addition to their porous nature. This class of BILPs has shown that the extended-conjugated system improved BILPs electronic properties. The other studies performed in this research, involved the use of DFT theory to investigate CO2/BILPs interaction sites and binding affinities. The computational outcomes of DFT have shown that (C-H) bond of the aryl system is a possible site for CO2 interaction beside the free-N side and hydrogen bonding. All new polymers were characterized by spectral and analytical characterization methods and their sorption data were collected to evaluate their capability as candidates for gas separation applications.