Hydrothermal preparation membranes

The silicalite-alumina membrane was prepared after adding a solution containing the silicalite precursor (i e silica + template) to the above-mentioned porous tube (hereafter called support) and a specific hydrothermal treatment performed [8], under the chosen conditions no material is formed in the absence of the porous support. The tube is then calcined at 673 K for removing the template. 

Membranes with extremely small pores ( < 2.5 nm diameter) can be made by pyrolysis of polymeric precursors or by modification methods listed above. Molecular sieve carbon or silica membranes with pore diameters of 1 nm have been made by controlled pyrolysis of certain thermoset polymers (e.g. Koresh, Jacob and Soffer 1983) or silicone rubbers (Lee and Khang 1986), respectively. There is, however, very little information in the published literature. Molecular sieve dimensions can also be obtained by modifying the pore system of an already formed membrane structure. It has been claimed that zeolitic membranes can be prepared by reaction of alumina membranes with silica and alkali followed by hydrothermal treatment (Suzuki 1987). Very small pores are also obtained by hydrolysis of organometallic silicium compounds in alumina membranes followed by heat treatment (Uhlhom, Keizer and Burggraaf 1989). Finally, oxides or metals can be precipitated or adsorbed from solutions or by gas phase deposition within the pores of an already formed membrane to modify the chemical nature of the membrane or to decrease the effective pore size. In the last case a high concentration of the precipitated material in the pore system is necessary. The above-mentioned methods have been reported very recently (1987-1989) and the results are not yet substantiated very well. 

The in situ membrane growth technique cannot be applied using the zeolite-based ceramic porous membrane as support, under hydrothermal conditions in a solution containing sodium hydroxide. The high pH conditions will cause membrane amorphization and lead to final dissolution. Therefore, we tried to synthesize an aluminophosphate zeolite such as AlP04-5 [105] over a zeolite porous ceramic membrane. For the synthesis of the AlP04-5-zeolite-based porous membrane composite, the in situ membrane growth technique [7,13,22] was chosen. Then, the support, that is, the zeolite-based porous ceramic membrane, was placed in contact with the synthesis mixture and, subsequently, subjected to a hydrothermal synthesis process [18]. The batch preparation was as follows [106] ... 

The preparation and properties of hydrothermally stable y-alumina membranes... 

The intention of this chapter is to provide an overview of the research performed on silica membranes and membrane materials during the project. Due to the fact that subjects like the preparation of tubular supports and a hydrothermally stable intermediate layer were given a higher priority, most of the results are preliminary and much more research will be needed to get a clear picture of the behaviour of (doped) silica membranes under SASRA conditions. Therefore the results provided should be seen as the result of preliminary work and might serve as a basis for future research. 

The excellent separation properties of silica membranes prepared at temperatures as high as 825°C enables their use for high temperature applications, such as the dehydrogenation of H2S (chapter 8). Unfortunately no hydrothermal stability of the prepared layers could be tested because the mesoporous intermediate layer was not hydrothermally stable, but an indication of the hydrothermal stability of the unsupported material could be obtained from the specific surface area and XRD measurements. These measurements did not show any structural change in the material during SASRA treatment, which is a very hopeful result for the operation of real, supported, membranes at high temperatures and high pressures. 

For the application of microporous silica membranes in steam-containing environments it is of major importance that the silica membranes will be tested on hydrothermally stable supports. Silica membranes should be prepared on the basis of the results of the specific surface area measurements described in chapter 6. Unsupported silica membrane material of which the specific surface area does not change under SASRA conditions is most promising. An example is silica fired at 825°C (chapter 5). The need of doping the silica with foreign ions or atoms is currently uncertain. 

Different ways have been proposed to prepare zeolite membranes. A layer of a zeolite structure can be synthesized on a porous alumina or Vycor glass support [27, 28]. Another way is to allow zeolite crystals to grow on a support and then to plug the intercrystalline pores with a dense matrix [29], However, these two ways often lead to defects which strongly decrease the performance of the resulting membrane. A different approach consists in the direct synthesis of a thin (but fragile) unsupported monolithic zeolite membrane [30]. Recent papers have reported on the preparation of zeolite composite membranes by hydrothermal synthesis of a zeolite structure in (or on) a porous substrate [31-34]. These membranes can act as molecular sieve separators (Fig. 2), suggesting that dcfcct-frcc materials can be prepared in this way. The control of the thickness of the separative layer seems to be the key for the future of zeolite membranes. 

Gavalas et al. [7] prepared ZSM-5 membranes onto porous a-alumina disks by in-situ hydrothermal synthesis at 175°C. The zeolite layers were formed on the bottom face of disks placed horizontally near the air-liquid interface of clear synthesis solutions. The films grown at the optimized conditions were about 10 pm thick and consisted of well-intergrown crystals of about 2 pm in size Pure gas permeation measurements of the best preparations yielded hydrogen isobutane and butane isobutane ratios of 151 and 18 at room temperature and of 54 and 31 at 185°C, respectively. 

Hardly any research has been performed on ferrierite in zeolite membrane configurations. Matsukada et al. [50,51] prepared a ferrierite-based membrane by the frequently used Vapour-phase Transport Method. By using ethylenediamine, triethylamine and steam (under hydrothermal conditions), a porous alumina support, covered with the proper aluminosilicate gel, was transformed into a alumina supported (30 pm thick) ferrierite layer. No permeation with 1,3,5-triisopropylbenzene coirld be observed, proving the layer to be defect-free. Fluxes of small gases were found in the order of 10" -10 mol.m. s. Pa and decreased in the order H2>He>CH4>N2>02>C02... 

Supported zeolite membranes have been prepared using numerous procedures [4] such as alignment of crystals in electrical fields, electroplating, self-assembly, growth on organic molecular layers, covalent linkages, hydrothermal synthesis (in situ and ex situ), hydrothermal method microwave heating assisted, dry gel method (vapor-phase transport method and steam-assisted crystallization), synthesis at the interface between two fluid phases, etc. 

A survey of recent literature on zeolite membrane preparation reveals that synthesis processes, even for well-known zeolite structures (i.e., MFl, LTA), are still carried out batchwise, using a hydrothermal route to produce a thin layer from hydrogels or sols containing the corresponding nutrients. As a general rule, the reactant mixture in contact with the support changes in composition with time provoking a reduction of the membrane quality. 

Basically, the hydrothermal synthesis procedures used to prepare zeolite membranes can be classified in two general groups ex situ and in situ methods, that is with and without a previous seeding step, which are briefly discussed below. 

Silicalite-1 membranes, supported on porous alumina ceramic discs, have been prepared by two different routes. In the first the zeolite membrane has been formed by in situ hydrothermal synthesis. Secondly a layer has been formed by controlled filtration of zeolite colloids. To optimise membrane stability, conditions have been established in which penetration of zeolite into the support sublayer occurs. The pore structure of these membranes has been characterised by a combination of SEM and Hg-porosimetry. The permeabilities of several gases have been measured together with gas mbeture separation behaviour. 

Thin zeolite membranes can also be prepared through a spin-coating process of a nanoparticle suspension. Yan and coworkers synthesized silicalite-1 and silicalite-2 in a nanoparticle suspension using a two-stage hydrothermal process.[138,139] First, the precursor... 

Polycrystalline zeolite membranes consist of inter-grown zeolite crystals with no apparent cracks or pinholes (Fig. lA). These films are composed of only zeolite (i.e., there are no non-zeolite components such as amorphous silica or polymer). They are normally supported on a substrate although free-standing films have also been synthesized. Membranes can be prepared on different substrates such as silicon wafer, quartz, porous alumina, carbon, glass, stainless steel (SS), gold, etc. Polycrystalline films are primarily prepared by hydrothermal synthesis methods including in situ crystallization, seeded growth,and vapor transport, " and have potential use in all of the applications discussed in this entry. 

In order to accelerate the synthesis of both zeolite seeds and membranes, microwave-assisted hydrothermal synthesis (MW-HT) revealed an attractive method. Colloidal zeolite seeds can be successfully prepared by MW-HT synthesis [100,112,113]. Starting from a seeded support,... 

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