Mixed-matrix hollow fiber membranes are being developed to offer more efficient gas separations applications than what the current technologies allow. Mixed-matrix membranes (MMMs) are membranes in which molecular sieves incorporated in a polymer matrix do separation between gas mixtures based on the molecular size difference and/or adsorption properties of the component gases vis-à-vis the porous structure and the nature of adsorption sites in the molecular sieve. The development of MMMs to deliver on its promises has however been slow. The major challenges encountered in the efficient development of MMMs are associated with some of the paradigm shifts involved in their processing. For instance, mixed-matrix hollow fiber membranes are prepared by a dry-wet jet spinning method. For an efficient large scale processing of hollow fibers the rheology and kinetics of phase separation of the MMM dopes are important control variables in the process design. Therefore, this research thesis aims to study the rheology and phase separation kinetics of mixed-matrix membrane dopes. In research efforts to develop predictive models for the shear rheology of suspensions of zeolite particles in polymer solutions it was found that MFI zeolite suspensions have relative viscosities that dramatically exceed the Krieger-Dougherty predictions for hard sphere suspensions. Our investigations show that the major origin of this discrepancy is the selective absorption of solvent molecules from the suspending polymer solution into the zeolite pores. Consequently, both the viscosity of the polymer solution and the particle contribution to the suspension viscosity are greatly increased. A predictive model for the viscosity of porous zeolite suspensions incorporating a solvent absorption parameter, α, into the Krieger-Dougherty model was developed. We experimentally determined the solvent absorption parameter and our results are in good agreement with the theoretical pore volume of MFI particles. In addition, fundamental studies were conducted with spherical nonporous silica suspensions to elucidate the role of colloidal and hydrodynamic forces on the rheology of mixed-matrix membrane dopes. Also in this thesis, details of a novel microfluidic device that enables measurements of the phase separation kinetics via video-microscopy are presented. Our device provides a well-defined sample geometry and controlled atmosphere for in situ tracking of the phase separation process. We have used this technique to quantify the phase separation kinetics (PSK) of polymer solutions and MMM dopes upon contact with an array of relevant nonsolvent. For the polymer solution, we found that PSK is governed by the micro-rheological and thermodynamic properties of the polymer solution and nonsolvent. For the MMM dopes, we found that the PSK is increased by increased particles surface area as a result of surface diffusion enhancement. In addition, it was found that the dispersed particles alter the thermodynamic quality of the dope based on the hydrophilic and porous nature of suspended particles.

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 goal of this project was to understand and model the performance of hybrid inorganic-organic membranes under realistic operating conditions for hydrocarbon gas/vapor separation, using butane isomers as the model vapors and a hybrid membrane of 6FDA-DAM-5A as an advanced separation system. To achieve the set goal, three objectives were laid out. The first objective was to determine the factors affecting separation performance in dense neat polymer. One main concern was plasticization. High temperature annealing has been reported as an effect means of suppressing plasticization. A study on the effect of annealing temperature was performed by analyzing data acquired via sorption and permeation measurements. Based on the findings from this study, a suitable annealing temperature was determined. Another factor studied was the effect of operating temperature. In deciding a suitable operating temperature, factors such as its possible effect on plasticization as well as reducing heating/cooling cost in industrial application were considered. Based on the knowledge that industrial applications of this membrane would involve mixture separation, the second objective was to understand and model the complexity of a mixed gas system. This was investigated via permeation measurements using three feed compositions. An interesting transport behavior was observed in the mixed gas system, which to the best of our knowledge, has not been observed in other mixed gas systems involving smaller penetrants. This mixed gas transport behavior presented a challenge in predictability using well-established transport models. Two hypotheses were made to explain the observed transport behavior, which led to the development of a new model termed the HHF model and the introduction of a fitting parameter termed the CAUFFV fit. Both the HHF model and CAUFFV fit showed better agreement with experimental data than the well-established mixed gas transport model. The final objective was to explore the use of mixed matrix membranes as a means of improving the separation performance of this system. A major challenge with the fabrication of good mixed matrix membranes was the adhesion of the zeolite particle with the polymer. This was addressed via sieve surface modification through a Grignard treatment process. Although a Grignard treatment procedure existed, there was a challenge of reproducibility of the treatment. This challenge was addressed by exploring the relationship between the sieves and the solvent used in the treatment, and taking advantage of this relationship in the Grignard treatment process. This study helped identify a suitable solvent, which allowed for successful and reproducible treatment of commercial LTA sieves; however, treatment of lab-made sieves continues to prove challenging. Based on improved understanding of the Grignard treatment reaction mechanism, modifications were made to the existing Grignard treatment procedure, resulting in the introduction of a "simplified" Grignard treatment procedure. The new procedure requires less control over the reaction process, thus making it more attractive for industrial application. Permeation measurements were made using mixed matrix membranes in both single and mixed gas systems. Selectivity enhancements were observed under both single and mixed gas systems using sieve loadings of 25 and 30wt%. The Maxwell model was used to make predictions of mixed matrix membrane performance. Although the experimental results were not in exact agreement with Maxwell predictions, the observed selectivity enhancement was very encouraging and shows potential for future application. Recommendations were made for future study of this system.

Defect generation and propagation in thin films, such as separation membranes, can lead to premature or catastrophic failure of devices such as polymer electrolyte membrane fuel cells (PEMFC). It is hypothesized that defects (e.g., air bubbles, pin-holes, and holes) originate during the manufacturing stage, if precise control is not maintained over the coating process, and they propagate during system operation. Experimental and numerical studies were performed to detect and eliminate defects that were induced during slot die coating of high-viscosity (1 to 40 Pa-s), shear-thinning solutions. The effects of fluid properties, geometric parameters and processing conditions on air entrainment and coating windows (limited set of processing conditions for which defect-free coating exists) were studied. When smaller slot gaps and coating gaps were used, relatively small bubbles were entrained in the coated film. The air bubble sizes increased as the viscosity of the coating solution decreased. A semi-empirical model correlating the maximum coating speed to a solution's material properties, geometric parameters and processing conditions was developed. Such a predictive model will enable engineers to determine the maximum coating boundary for shear-thinning and Newtonian solutions within certain constraints. Smaller coating gaps and low-viscosity solutions produced higher coating speeds. The surface tension property of the coating solution provided stability to the coating bead. Therefore, solutions with higher surface tension could be processed at higher coating speeds.

First- principles modeling is used to predict hydrogen permeability through Palladium (Pd)-rich binary alloy membranes as a function of temperature and H2 pressure. We introduce a simplified model that incorporates only a few factors and yields quantitative prediction. This model is used to predict hydrogen permeability in a wide range of binary alloy membranes and to find promising alloys that have high hydrogen permeability. We show how our efficient Density Functional Theory (DFT)-based model predicts the chemical stability and proton conductivity of doped barium zirconate (BaZrO3), barium stannate (BaSnO3), and barium hafnate (BaHfO3). Our data is also used to explore the physical origins of the trends in chemical stability and proton conductivity among different dopants. We also study potassium tantalate (KTaO3), which is a prototype perovskite, to examine the characteristics of undoped perovskites. Specifically, we study the impacts of isotope effects, tunneling effects, and native point defects on proton mobility in KTaO3. It is important to find and develop solid-state Li-ion electrolyte materials that are chemically stable and have high ionic conductivities for high performance Li-ion batteries. We show how we predict the chemical stability of Li7La3Zr2O12, Li7La3Sn2O12, and Li7La3Hf2O12 with respect to carbonate and hydroxide formation reactions.

Mixed matrix membranes (MMMs) consisting of a polymer bulk phase and an inorganic dispersed phase have the potential to provide a more selective membrane because they incorporate the selectivity of a zeolite dispersed phase while maintaining the ease of use of a polymer membrane. A critical problem in MMM applications is control over the polymer-zeolite interface adhesion during fabrication which can detrimentally impact membrane performance. In this work, MgOxHy (1≤x≤2, 0≤y≤2) nanostructures have been grown on pure-silica MFI and aluminosilicate LTA zeolites through four surface deposition techniques: Grignard decomposition reactions, solvothermal and modified solvothermal depositions, and ion-exchange induced surface crystallization. The structural properties of the surface nanostructures produced by each of the four methods were thoroughly characterized for their morphology, crystallinity, porosity, surface area, elemental composition, and these properties were used to predict the method’s suitability for use in composite membranes. The nanostructured zeolites were used in mixed matrix membranes (MMMs) at two MMMs weight loadings. The dispersion, mechanical properties, and CO₂/CH₄ gas separation properties were measured MMMs made with each method of functionalized LTA. All functionalization methods improve adhesion with the polymer observable by microscopy, the dispersion of particles, and the elastic modulus and hardness of the membrane. Gas permeation measurements prove the quality and effectiveness of the Ion Exchange membrane for CO₂/CH₄ separation by its significant increase in selectivity over the pure polymer. Lastly, the interface between the two materials was studied by probing the interfacial polymer mobility using NMR spin-spin relaxation measurements and mechanical mapping of membrane cross sections. It was shown that the nanostructures have both steric and chemical interactions with the polymer. Mapping of the elastic modulus indicated that functionalization methods that resulted in poorer zeolite coverage also disrupted the mechanical properties of the membrane at the interface of the materials. The investigations in this thesis provide detailed structure-property relationships of surface-modified molecular sieves and nanocomposite membranes fabricated using these materials, allowing a rational approach to the design of such materials and membranes.

The overall focus of this thesis is on the development and understanding of nanoporous layered silicates and membranes, particularly for potential applications in gas separations. Nanoporous layered materials are a rapidly growing area of interest, and include materials such as layered zeolites, porous layered oxides, layered aluminophosphates, and porous graphenes. They possess unique transport properties that may be advantageous for membrane and thin film applications. These materials also have very different chemistry from 3-D porous materials due to the existence of a large, chemically active, external surface area. This feature also necessitates the development of innovative strategies to process these materials into membranes and thin films with high performance.

Polymer electrolyte membrane fuel cells (PEMFCs) have been looked as potential alternative energy conversion devices to conventional energy conversion systems such as combustion engines. Proton conducting membranes (PEMs) are one critical component of PEMFCs. The development of novel electrolyte membranes with dense structure, good mechanical flexibility, and high proton conductivity, but with little or no dependence on humidity at temperatures above 100¡ãC remains an important challenge to the realization of practical PEM fuel cells. In this thesis, to solve the technical difficulties existing in current high temperature PEM systems based on phosphoric acid and imidazole, a new type of proton conducting species 1H-1,2,3-triazole has been explored, and proved to have high proton conductivity and also enough electrochemical stability for fuel cell applications. In further experiments, effective methods have been developed to synthesize triazole derivatives and polymers. The properties of the synthesized polymers have studied and reported in this thesis. Preliminary computational simulations have also been performed to study the proton conducting mechanism to provide intrinsic information of the proton conducting process in 1H-1,2,3-triazole. In the final part, research works on other proton conducting species including H3PO4 and other heterocycles have been reported.

An important challenge for PEMFC is stability and durability of the membrane separator. In this dissertation, we applied both experimental and modeling methods to investigate the chemical durability of PFSA membranes for fuel-cell applications. Degradation data were collected after Fenton's tests and the membrane samples were analyzed by XPS after Fenton's test; FTIR was also invoked to validate the XPS results. The effects of Fe2+ concentration and temperature on membrane degradation were discussed. The experimental results provide evidence of chemical attack of the CF2 backbone. Since the level of H2O2 was found to be key to membrane degradation, we designed a novel spectrophotometric method to quantitatively determine H2O2 concentration in a fuel cell by using a multilayer MEA. In addition, a model for H2O2 formation, transport, and reaction in PEMFCs is established for the first time to validate experimental data and study formation mechanism. The humidity effect on membrane degradation was studied by collecting vent water during the tests. The membrane conductivities and mechanical properties were measured by ex-situ high-throughput instruments. FTIR was applied to study both the formation of new groups and the relative abundance of existing groups in the degraded membrane. The thermal stability of degraded membranes was determined by TGA. The cross section of a degraded MEA sample was imaged with SEM to investigate the mechanical structure change. The effect of temperature on membrane degradation was also investigated. XPS spectra were collected from both anode and cathode sides of fuel-cell membrane to compare the effect of temperature on each side. Atomic analysis was performed to study the impact of temperature on both backbone decomposition and side group degradation. A multilayer MEA was used to study the effects of location and thickness on membrane degradation. An improved kinetic model of membrane degradation was built to simulate the experimental data. Finally, an attempt to mitigate membrane degradation by using peroxide decomposition reagent was performed. OCV curves were recorded during two fuel-cell durability tests with and without the addition of this additive. Both FER and TER were compared. Recommendations for the improvement of peroxide decomposition additive were suggested.

Thesis (Ph. D.)--Ohio State University, 2008.