Fabrication and Evaluation of Trimethylmethoxysilane (TMMOS)-Derived Membranes for Gas Separation

Synthesis and Characterization of Silica-Tantala Microporous Membranes for Gas Separations Fabricated Using Chemical Vapor Deposition

Composite membranes consisting of microporous tantalum-doped silica layers supported on mesoporous alumina substrates were fabricated using chemical vapor deposition (CVD) in both thermal decomposition and counter-flow oxidative deposition modes. Tetraethyl orthosilicate (TEOS) was used as the silica precursor and tantalum (V) ethoxide (TaEO) as the tantalum source. Amounts of TaEO from 0 mol% to 40 mol% were used in the CVD gas mixture and high H₂ permeances above 10^-7 mol m^-2 s^-1 Pa^-1 were obtained for all conditions. Close examination was made of the H₂/CH₄ and O₂/CH₄ selectivities due to the potential use of these membranes in methane reforming or partial oxidation of methane applications. Increasing deposition temperature correlated with increasing H₂/CH₄ selectivity at the expense of O₂/CH₄ selectivity, suggesting a need to optimize membrane synthesis for a specific selectivity. Measured at 400 °C, the highest H₂/CH₄ selectivity of 530 resulted from thermal CVD at 650 °C, whereas the highest O₂/CH₄ selectivity of 6 resulted from thermal CVD at 600 °C. The analysis of the membranes attempted by elemental analysis, X-ray photoelectron spectroscopy, and X-ray absorption near-edge spectroscopy revealed that Ta was undetectable because of instrumental limitations. However, the physical properties of the membranes indicated that the Ta must have been present at least at dopant levels. It was found that the pore size of the resultant membranes increased from 0.35 nm for pure Si to 0.37 nm for a membrane prepared with 40 mol% Ta. Similarly, an increase in Ta in the feed resulted in an increase in O₂/CH₄ selectivity at the expense of H₂/CH₄ selectivity. Additionally, it resulted in a decrease in hydrothermal stability, with the membranes prepared with higher Ta suffering greater permeance and selectivity declines during 96 h of exposure to 16 mol% H₂O in Ar at 650 °C.

Hydrogen Selective SiCH Inorganic-Organic Hybrid/γ-Al2O3 Composite Membranes

Solar hydrogen production via the photoelectrochemical water-splitting reaction is attractive as one of the environmental-friendly approaches for producing H₂. Since the reaction simultaneously generates H₂ and O₂, this method requires immediate H₂ recovery from the syngas including O₂ under high-humidity conditions around 50 °C. In this study, a supported mesoporous γ-Al₂O₃ membrane was modified with allyl-hydrido-polycarbosilane as a preceramic polymer and subsequently heat-treated in Ar to deliver a ternary SiCH organic–inorganic hybrid/γ-Al₂O₃ composite membrane. Relations between the polymer/hybrid conversion temperature, hydrophobicity, and H₂ affinity of the polymer-derived SiCH hybrids were studied to functionalize the composite membranes as H₂-selective under saturated water vapor partial pressure at 50 °C. As a result, the composite membranes synthesized at temperatures as low as 300–500 °C showed a H₂ permeance of 1.0–4.3 × 10⁻⁷ mol m⁻² s⁻¹ Pa⁻¹ with a H₂/N₂ selectivity of 6.0–11.3 under a mixed H₂-N₂ (2:1) feed gas flow. Further modification by the 120 °C-melt impregnation of low molecular weight polycarbosilane successfully improved the H₂-permselectivity of the 500 °C-synthesized composite membrane by maintaining the H₂ permeance combined with improved H₂/N₂ selectivity as 3.5 × 10⁻⁷ mol m⁻² s⁻¹ Pa⁻¹ with 36. These results revealed a great potential of the polymer-derived SiCH hybrids as novel hydrophobic membranes for purification of solar hydrogen.

Synthesis of Silica Membranes by Chemical Vapor Deposition Using a Dimethyldimethoxysilane Precursor

Silica-based membranes prepared by chemical vapor deposition of tetraethylorthosilicate (TEOS) on γ-alumina overlayers are known to be effective for hydrogen separation and are attractive for membrane reactor applications for hydrogen-producing reactions. In this study, the synthesis of the membranes was improved by simplifying the deposition of the intermediate γ-alumina layers and by using the precursor, dimethyldimethoxysilane (DMDMOS). In the placement of the γ-alumina layers, earlier work in our laboratory employed four to five dipping-calcining cycles of boehmite sol precursors to produce high H₂ selectivities, but this took considerable time. In the present study, only two cycles were needed, even for a macro-porous support, through the use of finer boehmite precursor particle sizes. Using the simplified fabrication process, silica-alumina composite membranes with H₂ permeance > 10^-7 mol m^-2 s^-1 Pa^-1 and H₂/N₂ selectivity >100 were successfully synthesized. In addition, the use of the silica precursor, DMDMOS, further improved the H₂ permeance without compromising the H₂/N₂ selectivity. Pure DMDMOS membranes proved to be unstable against hydrothermal conditions, but the addition of aluminum tri-sec-butoxide (ATSB) improved the stability just like for conventional TEOS membranes.