Membrane for Gas Phase Separation and Suitable Method for the Production Thereof

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This patent describes a method for producing a high-performance, microporous ceramic membrane composed of nanocrystalline zeolite layers on a porous support. The membrane features extremely fine pore sizes (0.2 to 0.45 nm), making it ideal for selectively separating various gases in industrial settings. The process uses a colloidal solution with nanoscale zeolite crystallites, which is applied to the substrate and then hydrothermally treated to create a temperature- and chemically-resistant membrane with precise, defect-minimized pores.

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• Separation of gas mixtures in power plants or industrial facilities (e.g., separating CO2 from flue gases to reduce emissions)
• Oxygen or nitrogen production by separating N2/O2 from air
• Hydrogen purification or CO2 removal for clean fuel applications
• Methane (natural gas) purification by separating CO2/CH4
• Integration into high-temperature industrial processes where robust gas separation membranes are needed
• Use in chemical processing for selective removal or purification of specific gases

BenefitsContent extracted from patent full text and abstract with AI.

• Highly selective separation due to finely-tuned, uniform pore sizes
• Enhanced thermal and chemical stability, allowing operation directly within high-temperature or harsh industrial processes
• Defect-minimized membrane structure leads to improved separation efficiency and gas flux
• Versatility to separate a range of important industrial gas pairs (N2/O2, N2/CO2, H2/CO2, CO2/CH4)
• Potential to improve the energy efficiency and cost-effectiveness of industrial gas separation, especially in power generation and carbon capture
• Scalability through controllable membrane thickness and substrate material choices

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Patent Abstract

The invention relates to a method for the hydrothermal production of a microporous membrane. According to said method, a colloidal solution comprising zeolite frameworks with 4-ring, 6-ring, and/or 8-ring pores which are provided as crystallites whose size ranges from 2 to 25 nm is applied to a porous substrate with the aid of a wet application technique. The applied layer is contacted with a hydrothermal liquid, and a nanocrystalline, microporous zeolite layer having an average pore diameter of 0.2 to 0.45 nm is synthesized at temperatures ranging between 50 and 250 °C and at an autogenous pressure. Such a microporous membrane comprising a porous substrate and at least one nanocrystalline zeolite layer that is disposed thereupon and has an average pore diameter of 0.2 to 0.45 nm is advantageously suitable for use as a separating device for gas phase separation, making it possible to separate particularly N2/O2, N2/CO2, H2/CO2, or CO2/CH4 gas mixtures. Said separating device is especially temperature-resistant and can therefore be integrated directly into thermal processes.