Recent developments have confirmed that in the future hydrogen demand in industrial applications will arise because of the growing requirements for H2 in chemical manufacturing, petroleum refining, and the newly emerging clean energy concepts. Hydrogen is mainly produced from the steam reforming of natural gas and water gas shift reactions. The major products of these processes are hydrogen and carbon dioxide. The selective removal of CO2 from the product gas is important because it poisons catalysts in the reactor and it is highly corrosive. Membrane separation processes for hydrogen purification may be employed as alternative for conventional methods such as adsorption, cryogenic distillation. Mixed matrix membranes (MMMs) are composed of an insoluble phase dispersed homogeneously in a continuous polymer matrix. They have potential in gas separation applications by combining the advantageous properties of both phases. The objective of this study is to produce neat polybenzimidazole (PBI) membranes and PBI based mixed matrix membranes for separation of H2/CO2. Furthermore, to test the gas permeation performance of the prepared membranes at permeation temperatures of 35oC to 90oC. Commercial PBI supplied from both Celanese and FumaTech were used as polymer matrix. PBI was selected based on its thermal, chemical stabilities and mechanical properties and its performance as a fuel-cell membrane produced by PBI. Micro-sized Zeolite 3A and nano-sized SAPO-34 are zeolites with 0.30 nm and 0.38 nm pore size respectively have attracted considerable interest and employed as fillers in this study. Commercial Zeolite 3A and synthesized SAPO-34 by our group was used throughout the study. Membranes were prepared using N,N-dimethylacetamide as the solvent. Prepared membranes were characterized by scanning electron microscopy (SEM), differential scanning calorimetry (DSC) and thermal gravimetric analysis (TGA). The effect of annealing procedure and operating temperature on gas separation performance of resultant neat PBI, PBI/Zeolite 3A and PBI/SAPO-34 membranes were investigated by gas permeation tests. Hydrogen and carbon dioxide gases were used for single gas permeation measurements. Two different annealing strategies were utilized namely in-line annealing and in-oven annealing. In-oven annealing was performed in an oven in nitrogen atmosphere at 120oC, 0.7 atm while in-line annealing was performed in the gas permeation set-up by feeding helium as permeating gas at 90oC and 3 bar. Neat PBI and PBI/ Zeolite 3A membranes were in-oven annealed. The in-oven annealed membranes showed better selectivities with lower permeabilities, but the performance results of these membranes had low repeatability. On the other hand, in-line annealed membranes showed much higher permeabilities and lower selectivities with stable performance. By changing the annealing method hydrogen permeability increased from 5.16 Barrer to almost 7.77 barrer for neat membranes and for PBI/Zeolite 3A mixed matrix membranes increased from 5.55 to to 7.69 Barrer at 35oC. The selectivities were decreased from 6.21 to 2.31 for neat membranes and for PBI/Zeolite 3A from 5.55 to 2.63. Effect of increasing operating temperature was investigated by using in-line annealed membranes. Increasing temperature from 35oC to 90o improved the performance of the both types of membranes and repeatable results were obtained. Besides neat PBI and PBI/Zeolite 3A, PBI/SAPO-34 membranes were prepared only via in-line annealing. The addition of nano-sized filer to the membranes provided homogeneous distribution in polymer matrix for PBI/SAPO-34 membranes. For this type of membrane hydrogen permeability increased from 8.01 to 26.73 Barrer and with no change in H2/CO2 selectivities via rising temperature. Consequently, it is better to study hydrogen and carbon dioxide separation at high temperature. For all types of membranes hydrogen showed higher activation energies. In between all membranes magnitude of activation energies were the highest for PBI/SAPO-34 membrane which is an indication of good interaction between polymer and zeolite interface. In-line annealed membranes gave the best gas permeation results by providing repeatability of measurements. Among all studied membranes in-line annealed PBI/SAPO-34 membrane exhibited the best gas permeation results.

Crosslinkable mixed matrix membranes represent an attractive technology that promises both outstanding separation properties and swelling resistance for the purification of natural gas. This approach relies upon dispersal of a CO2/CH4 size-discriminating zeolite in a crosslinkable polymer, which is resistant to CO2 swelling when crosslinked. The resulting membrane has the potential to separate CO2 from CH4 more effectively than traditional pure polymer membranes, while also providing needed membrane stability in the presence of aggressive CO2-contaminated natural gas streams. Control studies are conducted using the pure crosslinkable polymer to observe the separation properties and swelling resistance. Initial crosslinkable mixed matrix membrane experiments are then performed and result in an increase in membrane productivity, instead of the expected increase in selectivity. Traditionally, this is caused by material incompatibility at the polymer/zeolite interface, so the crosslinkable mixed matrix membranes are characterized to examine this issue. During the material characterization, a new non-ideal transport phenomenon is discovered in the zeolite phase. A model is developed to better understand the transport and predict subsequent experimental results. Once the independent materials are proven to be viable, crosslinkable mixed matrix membranes that show enhancements in both efficiency and productivity and exhibit stability in the presence of aggressive CO2 feeds are created.

Mixed matrix membranes offer an attractive route to the development of high performance and efficiency membranes required for demanding gas separations. Such membranes combine the advantageous processing characteristics of polymers with the excellent separation productivity and efficiency of molecular sieving materials. This research explores the development of mixed matrix membranes, namely in the form of asymmetric hollow fiber membranes using zeolites as the molecular sieving phase and commercially available high performance polymers as the continuous matrix. Lack of adhesion between the typically hydrophobic polymer and the hydrophilic native zeolite surface is a major hurdle impeding the development of mixed matrix membranes. Silane coupling agents have been used successfully to graft polymer chains to the surface of the zeolite to increase compatibility with the bulk polymer in dense films. However, transitioning from a dense film to an asymmetric structure typically involves significant processing changes, the most important among them being the use of phase separation to form the asymmetric porous structure. During the phase separation, it is believed that hydrophilic sieves can act as nucleating agents for the hydrophilic polymer lean phase. Such nucleation tendencies are believed to lead to the formation of gaps between the polymer and sieve resulting in poor mixed matrix performance. This research focuses on defining procedures and parameters to form successful mixed matrix hollow fiber membranes. The first part of this dissertation describes dope mixing procedures and unsuccessful results obtained using a silane coupling agent to enhance polymer-zeolite adhesion. The next section follows the development of a highly successful surface modification technique, discovered by the author, employing the use of a Grignard reagent. As a test case, two zeolites of different silicon-to-aluminum ratios are successfully modified and used to develop mixed matrix membranes with greatly increased gas separation efficiencies. The broad applicability of the surface treatment is also demonstrated by the successful incorporation of the modified zeolites in a second polymer matrix. The final section of the work describes the novel occurrence of large defects (macrovoids) caused by the presence of large zeolite particles proposing a particle size effect in the formation of such defects.

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.

The goal of this project was to develop a mixed matrix membrane with enhanced properties for propylene/propane separations. To start with the project, one of the high performance 6FDA based polyimides was identified as the polymer matrix for the rest of the project. The chosen polymer (6FDA-6FpDA) was successfully synthesized in the laboratory. During the synthesis process the key objectives for high molecular weight and low polydispersity index polymer were identified. High molecular weight 6FDA-6FpDA was achieved via laboratory synthesis and was tested successfully. After successful synthesis of the high performance polymer, pure polymer dense films were tested for transport properties. One problem identified with 6FDA-6FpDA polymer films for propylene/propane separations was plasticization. A major objective of this research was to develop a method for plasticization suppression. A carefully controlled annealing procedure with high temperature permeation experiments was used in this research to suppress plasticization in a mixed gas environment. To the best of our knowledge, this is for the first time plasticization suppression was achieved with pure polymeric membrane material for propylene/propane separations with pure and mixed gases. The observed mixed gas experimental selectivity was lower than the pure gas selectivity which was explained by the combination effect of dual mode and bulk flow effect. The last objective of this project was to successfully incorporate molecular sieve materials to form a mixed matrix membrane hybrid material with enhanced transport properties First, an ideal molecular sieve for propylene/propane separation was identified and characterized. AlPO-14 was chosen for this research following its success with propylene/propane pressure swing adsorption. Mixed matrix membranes were successfully produced and tested for enhanced transport properties. Both pure and mixed gas results showed promising results with enhanced propylene permeability and propylene/propane selectivity. The experimental results were modeled with the Cussler and Maxwell models. A modified Cussler model was presented in this work. This is the first time an enhancement in the transport properties with mixed matrix membrane for propylene/propane separations has been observed. This fundamental dense film work holds a bright future for the scale up of propylene/propane separations.

Propylene is one of the most important feedstocks of the petrochemical industry with an estimated 2015 worldwide demand of 100 million tons. Retrofitting conventional C3 splitters is highly desirable due to the huge amount of thermal energy required to separate propylene from propane. Membrane separation is among the alternatives that both academia and industry have actively studied during the past decades, however; many challenges remain to advance membrane separation as a scalable technology for energy-efficient propylene/propane separations. The overarching goal of this research is to provide a framework for development of scalable ZIF-based mixed-matrix membrane that is able to deliver attractive transport properties for advanced gas separations. Zeolitic imidazolate frameworks (ZIFs) were pursued instead of conventional molecular sieves (zeolites and carbon molecular sieves) to form mixed-matrix membrane due to their intrinsic compatibility with high Tg glassy polymers. A systematic study of adsorption and diffusion in zeolitic imidazolate framework-8 (ZIF-8) suggests that this material is remarkably kinetically selective for C3 and C4 hydrocarbons and therefore promising for membrane-based gas separation and adsorptive separation. As a result, ZIF-8 was used to form mixed-matrix dense film membranes with polyimide 6FDA-DAM at varied particle loadings and it was found that ZIF-8 significantly enhanced propylene/propane separation performance beyond the “permeability-selectivity” trade-off curve for polymeric materials. Eventually, this research advanced ZIF-based mixed-matrix membrane into a scalable technology by successfully forming high-loading dual-layer ZIF-8/6FDA-DAM asymmetric mixed-matrix hollow fiber membranes with attractive propylene/propane selectivity.

Post-combustion carbon capture, wherein the CO2 produced as a result of coal combustion is trapped at the power plant exhaust, is seen as a bridging technology to reduce CO2 emissions and combat climate change. This capture process will however impose a parasitic load on the power plant and technologies need to be developed to minimize this energy penalty. This research focuses on a technology which uses solid sorbents fashioned into a hollow fiber form that allows water-moderated thermal cycling as a means of trapping CO2 from flue gas. While hollow fiber technology has intrinsic advantages over competing liquid amine and packed bed technologies, the materials used to fabricate hollow fibers and the fabrication process itself need to be optimized in order to result in competitive, robust hollow fiber sorbents. This dissertation focuses on the material selection process for each component of the hollow fiber platform and discusses ways to optimize the fiber and barrier layer formation. Different materials were evaluated to function as the solid sorbent, the matrix polymer and the barrier layer; and eventually their performance was measured against past work in this area.

For the last two decades, the possibility of using synthetic membranes for industrial gas separations has attracted considerable interest since membrane separation technologies have the advantages of energy efficiency, simplicity and low cost. However, for wider commercial utilization there is still a need to develop membranes with higher permeant fluxes and higher transport selectivities. Conductive polymers, due to their high gas transport selectivities, give rise to a new class of polymeric materials for membrane based gas separation though poor mechanical properties obstruct the applications for this purpose of use. This problem led researches to a new idea of combining the conducting polymers with insulating polymers forming mixed matrix composite membranes. In the previous studies in our group, polypyrrole was chosen as the conductive polymer, and different preparation techniques were tried and optimized for membrane application. As the insulating polymer, previously poly(bisphenol-Acarbonate) was used to support the conductive polymer filler in order to constitute a conductive composite membrane. For this study, as the polymer matrix, hexafluorobisphenol A based poly(arylene ether ketone) was targeted due to its physical properties and temperature resistance which can be important for industrial applications. First of all, permeabilities of N2, CH4, Ar, H2, CO2, and H2 were measured at varying temperatures ranging from 25&deg / C to 85&deg / C through a homogenous dense membrane of chosen polymeric material to characterize its intrinsic properties. Measurements were done using laboratory scale gas separation apparatus which makes use of a constant volume variable pressure technique. The permeability results were used for the calculations of permeation activation energies for each gas. These permeation activation energies were found to be differing slightly for each gas independently from the kinetic diameters of gases. In this study, mixed matrix membranes of conducting polymer, polypyrrole (PPy) and insulating polymer, hexafluorobisphenol A based poly(arylene ether ketone) (PAEK) were also prepared. It was observed that PAEK and PPy form a composite mixed matrix structure, which can function as permselective membrane. The effect of conducting polymer filler content was investigated with two different filler ratios. When comparing with the pure PAEK membranes, meaningful increases for both permeability and selectivity were obtained for some of the gases.

Membranes are a promising, effective and energy efficient separation strategy for effluent gases in the Reverse Water Gas Shift (RWGS) reaction to increase the overall conversion of CO2 to CO. This process involves a separation and recycling process to reuse the unreacted CO2 from the RWGS reactor. The carbon monoxide produced from this reaction, alongside hydrogen (composing syngas), can be used in the Fischer-Tropsch process to create synthetic fuel, turning stationary CO2 emissions into a useable resource. A literature review was performed to select suitable polymers with high CO2 permeability and selectivities of CO2 over CO and H2. PDMS (polydimethylsiloxane) was selected and commercial and in-house PDMS membranes were tested. The highest CO2 permeability observed was 5,883 Barrers, including a CO2/H2 selectivity of 21 and a CO2/CO selectivity of 9, with ternary gas feeds. HY zeolite, silica gel and activated carbon were selected from previous research for their CO2 separation capabilities, to be investigated in PDMS mixed matrix membranes in 4 wt % loadings. Activated carbon in PDMS proved to be the best performing mixed matrix membrane with a CO2 permeability of 2,447 Barrers and comparable selectivities for CO2/H2 and CO2/CO of 14 and 9, respectively. It was believed that swelling, compaction and the homogeneity of the selective layer were responsible for trends in permeability with respect to driving force. The HY and silica gel mixed matrix PDMS membranes were believed to experience constraints in performance due to particle and polymer interfaces within the membrane matrix.

abstract: Water recovery from impaired sources, such as reclaimed wastewater, brackish groundwater, and ocean water, is imperative as freshwater resources are under great pressure. Complete reuse of urine wastewater is also necessary to sustain life on space exploration missions of greater than one year’s duration. Currently, the Water Recovery System (WRS) used on the National Aeronautics and Space Administration (NASA) shuttles recovers only 70% of generated wastewater.1 Current osmotic processes show high capability to increase water recovery from wastewater. However, commercial reverse osmosis (RO) membranes rapidly degrade when exposed to pretreated urine-containing wastewater. Also, non-ionic small molecules substances (i.e., urea) are very poorly rejected by commercial RO membranes. In this study, an innovative composite membrane that integrates water-selective molecular sieve particles into a liquid-barrier chemically resistant polymer film is synthetized. This plan manipulates distinctive aspects of the two materials used to create the membranes: (1) the innate permeation and selectivity of the molecular sieves, and (2) the decay-resistant, versatile, and mechanical strength of the liquid-barrier polymer support matrix. To synthesize the membrane, Linde Type A (LTA) zeolite particles are anchored to the porous substrate, producing a single layer of zeolite particles capable of transporting water through the membrane. Thereafter, coating the chemically resistant latex polymer filled the space between zeolites. Finally, excess polymer was etched from the surface to expose the zeolites to the feed solution. The completed membranes were tested in reverse osmosis mode with deionized water, sodium chloride, and rhodamine solutions to determine the suitability for water recovery. The main distinguishing characteristics of the new membrane design compared with current composite membrane include: (1) the use of an impermeable polymer broadens the range of chemical resistant polymers that can be used as the polymer matrix; (2) the use of zeolite particles with specific pore size insures the high rejection of the neutral molecules since water is transported through the zeolite rather than the polymer; (3) the use of latex dispersions, environmentally friendly water based-solutions, as the polymer matrix shares the qualities of low volatile organic compound, low cost, and non- toxicity. / Dissertation/Thesis / Doctoral Dissertation Chemical Engineering 2016