This thesis investigates membrane gas separation and its application to post-combustion carbon capture from coal-fired power plants as alternative to the conventional amine absorption technology. The attention is initially focused on membrane module modelling, with the aim of obtaining more detailed predictions of the behaviour of the separation though spiral-wound and hollow-fibre modules. Both one- and bi-dimensional models are implemented, compared and tested for different separations. Module geometry is investigated as well as the effect on the performances due to possible fabrication defects. A key part of the work involves the integration of the customised models into UniSim® Design, the Honeywell process simulator. Thanks to the developed interface, multi-stage process designs are developed, compared with the available literature and linked to a rigorous economic analysis. In particular, a long-term indicator such as the Levelised Cost Of Electricity (LCOE) is evaluated and parametric analyses are conducted with respect to both material and process parameters.

This research aimed to develop new polymeric materials for use in membrane or adsorption processes for carbon dioxide capture. In particular, it explored the synthesis, characterization and properties of polymers incorporating a spiro-center. A dianhydride containing a spiro-center (An-1), suitable for use in the preparation of polyimides, was synthesized using a previously reported procedure. The spiro-center makes the structure of the resulting polymers (PIM-PIs) similar to polymers of intrinsic microporosity (PIMs), which are known for their high internal surface area and outstanding membrane permeation properties. PIM-polyimides PIM-PI-1 and PIM-PI-5 were successfully synthesized and characterized, and membranes prepared for permeation studies. For PIM-PI-5, gas permeation data were obtained for the first time and were shown to be in reasonable agreement with values predicted by a group contribution method. To produce membranes with even better gas permeation properties, hydroxyl-containing PIM-polyimides were introduced. The presence of a hydroxyl group in the ortho position of the imide linkage made it possible to thermally rearrange the PIM-polyimide to a PIM-polybenzoxazole (PIM-PBO) at 450 oC in an inert atmosphere. PIM-PI-OH-1 with high enough molecular weight to form a freestanding membrane was successfully synthesized using two different synthetic methods: thermal imidization and one-step polycondensation. The PIM-PI-OH-1 polymers prepared by both synthetic methods were compared in terms of gas permeation properties and CO2 uptake capacity, before and after thermal rearrangement. As expected, for polymers prepared by both methods, a significant enhancement was observed in the membranes gas permeation properties upon thermal rearrangement. Ethanol treatment was also performed on the thermally rearranged polymers, which resulted in a large increase in their permeability. The effect of aging was investigated on the ethanol treated PIM-PBO-1 membranes. It was observed that the membranes gradually lose the extra permeability created upon ethanol treatment and return to close to their original permeability value. To increase the concentration of thermally rearrangeable sites in the polymers, a dianhydride (An-2) with a smaller structure and lower molecular weight comparing to the An-1 was synthesized. A copolymer (copolymer-OH(1-2)), was synthesized using An-1 and An-2 (1:1). Gas permeation measurements were performed on the thermally rearranged polymer before and after ethanol treatment. A slight enhancement in the polymer’s selectivity toward CO2/N2 and CO2/CH4 gas pairs was observed, while maintaining the permeability. Having the same aim, PIM-PI-OH-3 was prepared using a smaller and a more rigid diamine, compared to the diamine used in the preparation of PIM-PI-OH-1. Gas permeation studies of the thermally rearranged membrane before and after ethanol treatment showed a significant increase in O2/N2 selectivity, which passed the Robeson 2008 upper bound. In adsorption experiments, CO2 uptake was higher than for PIM-PI-OH-1 and its thermally rearranged product.

Membrane based separation techniques have been widely used and developed over decades. Generally polymeric membranes are used in membrane based gas separation / however their gas separation performances are not sufficient enough for industrial feasibility. On the other hand inorganic membranes have good separation performance but they have processing difficulties. As a consequence mixed matrix membranes (MMMs) which comprise of inorganic particles dispersed in organic matrices are developed. Moreover, to enhance the interaction between polymer and zeolite particles ternary mixed matrix membranes are introduced by using low molecular weight additives as third component and promising results were obtained at 35 &deg / C. Better understanding on gas transport mechanism of these membranes could be achieved by studying the effect of preparation and operating parameters. This study investigates the effect of operation temperature and annealing time and temperature on gas separation performance of MMMs. The membranes used in this study consist of glassy polyethersulfone (PES) polymer, SAPO-34 particles and 2- v hidroxy 5-methyl aniline (HMA) as compatibilizer. The membranes fabricated in previous study were used and some membranes were used as synthesized while post annealing (at 120&deg / C, 0.2atm, N2 atm, 7-30 days) applied to some membranes before they are tested. The temperature dependent gas transport properties of the membranes were characterized by single gas permeation measurements of H2, CO2, and CH4 gases between 35 &deg / C-120 &deg / C. The membranes also characterized by scanning electron microscopy (SEM), thermal gravimetric analysis (TGA) and differential scanning calorimetry (DSC). Annealing time and temperature affected the reproducibility and stability of the mixed matrix membranes and by applying post annealing step to mixed matrix membranes at higher temperatures and longer times, more stable membranes were obtained. For pure PES membranes thermally stable performances were obtained without any need of extra treatment. The permeabilities of all studied gases increased with increasing operation temperature. Also the selectivities of H2/CO2 were increased while CO2/CH4, H2/CH4 selectivities were decreased with temperature. The best separation performance belongs to PES/SAPO-34/HMA mixed matrix membrane at each temperature. When the temperature increased from 35 &deg / C to 120 &deg / C H2/CO2 selectivity for PES/SAPO- 34/HMA membrane was increased from 3.2 to 4.6 and H2 permeability increased from 8 Barrer to 26.50 Barrer. This results show that for H2/CO2 separation working at higher temperatures will be more advantageous. The activation energies were found in the order of / CH4 &gt / H2&gt / CO2 for all types of membranes. Activation energies were in the same order of magnitude for all membranes but the PES/SAPO-34 membrane activation energies were slightly lower than PES membrane. Furthermore, PES/SAPO-34/HMA membrane has activation energies higher than PES/SAPO-34 membrane and is very close to pure membrane which shows that HMA acts as a compatibilizer between two phases.

京都大学 / 0048 / 新制・課程博士 / 博士(工学) / 甲第19686号 / 工博第4141号 / 新制||工||1639(附属図書館) / 32722 / 京都大学大学院工学研究科航空宇宙工学専攻 / (主査)教授 稲室 隆二, 教授 青木 一生講師杉元 宏 / 学位規則第4条第1項該当 / Doctor of Philosophy (Engineering) / Kyoto University / DFAM

This research aimed to develop new composite membranes using a polymer of intrinsic microporosity (PIM-1) and metal organic frameworks (MOFs) for use in gas separations. PIM-1 was successfully synthesised using the high temperature method (40 min, 160 oC) and the resulting polymer was cast into membranes. PIM-1 membranes were chemically modified by reacting hexamethylenediamine (HMDA) with the nitrile group of PIM-1 to form HMDA-modified PIM-1 membranes. Surfaces of PIM-1 membranes were also modified by basic hydrolysis to form amide-modified PIM-1 membranes. These polymer materials were characterized by different techniques (GPC, NMR, ATR-IR, TGA, Elemental analysis and nitrogen sorption analysis). In addition, eight MOF materials [MIL-101(Cr), ED-g-MIL-101(Cr), TEPA-g-MIL-101(Cr), MIL-101(Cr)-NH2, MIL-101(Al)-NH2, UiO-66(Zr), UiO-66-NH2 and UiO-66(COOH)2] were successfully synthesized. They were chosen due to having high surface areas and large porosity. These MOF compounds were characterized using PXRD, SEM, TGA, and low pressure N2.Successful PIM-1/MOF MMMs were fabricated utilising PIM-1 and the MOFs outlined above with various loadings. The highest MOF loading achieved was 28.6 wt. %, apart from MIL-101(Cr)-NH2, for which it was 23.1 wt. %, and MIL-101(Al)-NH2, for which it was 19.8 wt. %. The morphology of MMMs was characterized by scanning electron microscopy (SEM), proving the dispersion of MOF fillers. Novel PIM-1 supported MOF membranes were successfully prepared by depositing ZIF-8 and HKUST-1 layers on the surfaces of unmodified and modified PIM-1 membranes. These materials were characterized using PXRD, SEM, ATR-IR and SEM-EDX. Gas permeation properties of the MOF/PIM-1 MMMs and PIM-1 supported MOF membranes were determined using a time lag method. Most MMMs tested showed an increase in the permeability and stable selectivity as the MOF amount was increased. However, this was not true for MIL-101(Al)-NH2, where the permeability and selectivity decreased. In contrast, PIM-1 supported ZIF-8 and HKUST-1 membranes caused a sharp decrease in the permeability and increase in the selectivity.

Zeolite membranes are formed as a thin zeolitic layer on the supports. They are usually synthesized by hydrothermal methods in batch systems. In this study, MFI and SAPO-34 type zeolite membranes were produced on macroporous tubular alumina supports in a recirculating flow system at elevated temperatures for the first time in the literature. During the synthesis, the synthesis mixture is flown between the reservoir and the membrane module which includes the support material. The synthesis temperatures were 180&deg / C and 220&deg / C, and the corresponding system pressures were approximately 20 and 30 bars for MFI and SAPO-34, respectively. The CH4 and n-C4H10 single gas permeances were measured through MFI membranes and the performance of membranes was investigated in the separation of equimolar CH4/n-C4H10 mixtures. The best MFI membrane had a CH4 single gas permeance of 1.45x10-6 mol/m2-s-Pa and CH4/n-C4H10 ideal selectivity of 35 at 25oC. The membranes preferentially permeated n-C4H10 in the separation of mixtures. The n-C4H10/CH4 separation selectivity was 43.6 with a total permeance of approximately 0.8x10-6 mol/m2-s-Pa at 25oC. The ideal selectivities of CO2/CH4 of SAPO-34 membrane synthesized in stagnant medium were 227, and &gt / 1000 at 220 and 200oC, respectively. Formation of amorphous structure and the additional secondary phases (impurities) were observed on SAPO-34 membranes synthesized in recirculating flow system. The results showed that it is possible to produce SAPO-34 and high quality MFI membranes by a recirculating flow system operating at elevated temperature.

Coal-fired power plants are the largest anthropogenic point sources of CO2 emissions worldwide. About 40% of the world's electricity comes from coal. Approximately 49% of the US electricity in 2008 and 23% of the total electricity generation of Canada in 2000 came from coal-fired power plant (World Coal Association, and Statistic Canada). It is likely that in the near future there might be some form of CO2 regulation. Therefore, it is highly probable that CO2 capture will need to be implemented at many US and Canadian coal fired power plants at some point. Several technologies are available for CO2 capture from coal-fired power plants. One option is to separate CO2 from the combustion products using conventional approach such as chemical absorption/stripping with amine solvents, which is commercially available. Another potential alternative, membrane gas separation, involves no moving parts, is compact and modular with a small footprint, is gaining more and more attention. Both technologies can be retrofitted to existing power plants, but they demands significant energy requirement to capture, purify and compress the CO2 for transporting to the sequestration sites. This thesis is a techno-economical evaluation of the two approaches mentioned above along with another approach known as hybrid. This evaluation is based on the recent advancement in membrane materials and properties, and the adoption of systemic design procedures and optimization approach with the help of a commercial process simulator. Comparison of the process performance is developed in AspenPlus process simulation environment with a detailed multicomponent gas separation membrane model, and several rigorous rate-based absorption/stripping models. Fifteen various single and multi-stage membrane process configurations with or without recycle streams are examined through simulation and design study for industrial scale post-combustion CO2 capture. It is found that only two process configurations are capable to satisfy the process specifications i.e., 85% CO2 recovery and 98% CO2 purity for EOR. The power and membrane area requirement can be saved by up to 13% and 8% respectively by the optimizing the base design. A post-optimality sensitivity analysis reveals that any changes in any of the factors such as feed flow rate, feed concentration (CO2), permeate vacuum and compression condition have great impact on plant performance especially on power consumption and product recovery. Two different absorption/stripping process configurations (conventional and Fluor concept) with monoethanolamine (30 wt% MEA) solvent were simulated and designed using same design basis as above with tray columns. Both the rate-based and the equilibrium-stage based modeling approaches were adopted. Two kinetic models for modeling reactive absorption/stripping reactions of CO2 with aqueous MEA solution were evaluated. Depending on the options to account for mass transfer, the chemical reactions in the liquid film/phase, film resistance and film non-ideality, eight different absorber/stripper models were categorized and investigated. From a parametric design study, the optimum CO2 lean solvent loading was determined with respect to minimum reboiler energy requirement by varying the lean solvent flow rate in a closed-loop simulation environment for each model. It was realized that the success of modeling CO2 capture with MEA depends upon how the film discretization is carried out. It revealed that most of the CO2 was reacted in the film not in the bulk liquid. This insight could not be recognized with the traditional equilibrium-stage modeling. It was found that the optimum/or minimum lean solvent loading ranges from 0.29 to 0.40 and the reboiler energy ranges from 3.3 to 5.1 (GJ/ton captured CO2) depending on the model considered. Between the two process alternatives, the Fluor concept process performs well in terms of plant operating (i.e., 8.5% less energy) and capital cost (i.e., 50% less number of strippers). The potentiality of hybrid processes which combines membrane permeation and conventional gas absorption/stripping using MEA were also examined for post-combustion CO2 capture in AspenPlus®. It was found that the hybrid process may not be a promising alternative for post-combustion CO2 capture in terms of energy requirement for capture and compression. On the other hand, a stand-alone membrane gas separation process showed the lowest energy demand for CO2 capture and compression, and could save up to 15 to 35% energy compare to the MEA capture process depending on the absorption/stripping model used.

Coal-fired power plants are the largest anthropogenic point sources of CO2 emissions worldwide. About 40% of the world's electricity comes from coal. Approximately 49% of the US electricity in 2008 and 23% of the total electricity generation of Canada in 2000 came from coal-fired power plant (World Coal Association, and Statistic Canada). It is likely that in the near future there might be some form of CO2 regulation. Therefore, it is highly probable that CO2 capture will need to be implemented at many US and Canadian coal fired power plants at some point. Several technologies are available for CO2 capture from coal-fired power plants. One option is to separate CO2 from the combustion products using conventional approach such as chemical absorption/stripping with amine solvents, which is commercially available. Another potential alternative, membrane gas separation, involves no moving parts, is compact and modular with a small footprint, is gaining more and more attention. Both technologies can be retrofitted to existing power plants, but they demands significant energy requirement to capture, purify and compress the CO2 for transporting to the sequestration sites. This thesis is a techno-economical evaluation of the two approaches mentioned above along with another approach known as hybrid. This evaluation is based on the recent advancement in membrane materials and properties, and the adoption of systemic design procedures and optimization approach with the help of a commercial process simulator. Comparison of the process performance is developed in AspenPlus process simulation environment with a detailed multicomponent gas separation membrane model, and several rigorous rate-based absorption/stripping models. Fifteen various single and multi-stage membrane process configurations with or without recycle streams are examined through simulation and design study for industrial scale post-combustion CO2 capture. It is found that only two process configurations are capable to satisfy the process specifications i.e., 85% CO2 recovery and 98% CO2 purity for EOR. The power and membrane area requirement can be saved by up to 13% and 8% respectively by the optimizing the base design. A post-optimality sensitivity analysis reveals that any changes in any of the factors such as feed flow rate, feed concentration (CO2), permeate vacuum and compression condition have great impact on plant performance especially on power consumption and product recovery. Two different absorption/stripping process configurations (conventional and Fluor concept) with monoethanolamine (30 wt% MEA) solvent were simulated and designed using same design basis as above with tray columns. Both the rate-based and the equilibrium-stage based modeling approaches were adopted. Two kinetic models for modeling reactive absorption/stripping reactions of CO2 with aqueous MEA solution were evaluated. Depending on the options to account for mass transfer, the chemical reactions in the liquid film/phase, film resistance and film non-ideality, eight different absorber/stripper models were categorized and investigated. From a parametric design study, the optimum CO2 lean solvent loading was determined with respect to minimum reboiler energy requirement by varying the lean solvent flow rate in a closed-loop simulation environment for each model. It was realized that the success of modeling CO2 capture with MEA depends upon how the film discretization is carried out. It revealed that most of the CO2 was reacted in the film not in the bulk liquid. This insight could not be recognized with the traditional equilibrium-stage modeling. It was found that the optimum/or minimum lean solvent loading ranges from 0.29 to 0.40 and the reboiler energy ranges from 3.3 to 5.1 (GJ/ton captured CO2) depending on the model considered. Between the two process alternatives, the Fluor concept process performs well in terms of plant operating (i.e., 8.5% less energy) and capital cost (i.e., 50% less number of strippers). The potentiality of hybrid processes which combines membrane permeation and conventional gas absorption/stripping using MEA were also examined for post-combustion CO2 capture in AspenPlus®. It was found that the hybrid process may not be a promising alternative for post-combustion CO2 capture in terms of energy requirement for capture and compression. On the other hand, a stand-alone membrane gas separation process showed the lowest energy demand for CO2 capture and compression, and could save up to 15 to 35% energy compare to the MEA capture process depending on the absorption/stripping model used.

Für die hochselektive technische Trennung von Stoffen hält die Natur eine optimale Lösung namens Zeolithe bereit. In dieser Arbeit wurden Zeolith 4A in Form von Partikeln und wenig permeables Polymer in einer Membran kombiniert. Die Partikel lagen dabei in einer Monolage vor und wurden lediglich seitlich vom Polymer eingefasst, sodass sie beide Oberflächen der Polymerschicht durchbrachen. Diese Einbettung zu so genannten Zeolithkompositmembranen erlaubt einen Stofftransport ausschließlich durch die hochselektiven Zeolithpartikel. Die Herstellung und Charakterisierung der Zeolithkompositmembranen stehen im Mittelpunkt der vorliegenden Arbeit. Für die Membranherstellung kam das Prinzip der partikelassistierten Benetzung einer Wasseroberfläche zum Einsatz. Hierfür wurden die Zeolithpartikel beschichtet und anschließend das unverändert zugängliche Porensystem mittels Thermogravimetrie in Wasseradsorptions-Desorptionsmessungen nachgewiesen. Aus beschichteten Partikeln und passendem Monomer konnten schichtdickenoptimierte Zeolithkompositmembranen hergestellt werden. Es wurde eine Permeabilität P für Wasserdampf von 49 barrer festgestellt, während die Gase Stickstoff und Sauerstoff keinen Transportnachweis zuließen (P < 0,03 barrer). Daraus ergeben sich Selektivitäten von über 1600. Die Durchlässigkeit für Wasser beweist ein offenes Porensystem, die Impermeabilität für Stickstoff und Sauerstoff deutet auf eine sehr geringe Defektdichte hin, was beste Voraussetzungen für Trennmembranen darstellt. Das Herstellungsprinzip soll als Vorlage für die Präparation maßgeschneiderter Kompositmembranen mit wählbarer Porengröße dienen. Vergleiche zu konventionellen Zeolithmembranen belegen, dass die partikelassistierte Benetzung die Methode der Wahl ist, partikelförmiges hochselektives Material optimal einzubetten, ohne die begehrten Permeationseigenschaften zu beeinträchtigen. / An optimal material for highly selective separation processes can be found in zeolites. We prepared composite membranes composed of zeolite 4A particles and a polymer of low permeability. The particles formed a dense monolayer which were embedded into the polymer sheet in such a way that each particle prenetrates both the top and the bottom surface of the sheet. Only this embedding offffers a transport through the highly selective particles exclusively. This work focusses on these so called zeolite composite membranes, on their preparation and characterization. The preparation of the membranes was done via particle assisted wetting on a water surface. Therefore the zeolite particles were coated by a suitable silane agent and a blocking of the pore openings by the coating process was disproved by water adsorption-desorption measurements via TGA. Using the coated particles and a suitable monomer composite membranes could be formed and the optimum thickness was found. The membranes were permeable for water vapor (permeability P = 49 barrer), but impermeable for nitrogen and oxygene (P < 0,03 barrer (detection limit)). This results in a selectivity of above 1600. The permeability for water indicates that the molecules are transported through the zeolite channels. The impermeability for nitrogene and oxygene indicates a very low amount of defects. Furthermore the composite nature of the membrane reduces brittleness thus rendering it a promising candidate for separation technology with tailoring the pore size.