Water selective zeolite membranes

Table 15.2 Performances of water selective zeolite membranes...

Zhang Y, Wu Z, Hong Z, Gu X, Xu N. Hydrogen-selective zeolite membrane reactor for low temperature water gas shift reaction. Chem Eng J 2012 197 314—321. 

Zerva, C., Philippopoulos, C. J. (2006). Ceria catalysts for water gas shift reaction influence of preparation method on their activity. Applied Catalysis B Environmental, 67, 105—112. Zhang, Y., Wu, Z., Hong, Z., Gu, X., Xu, N. (2012). Hydrogen-selective zeolite membrane reactor for low temperature water gas shift reaction. Chemical Engineering Journal, 197, 314-321. 

The esterification of acetic acid with ethanol has been investigated using zeolite membranes grown hydrothermally on the surface of a porous cylindrical alumina support (the catalyst used was a cation exchange resin) [37]. The conversion exceeded the equilibrium limit, by the selective removal through the membrane of water and reached to almost 100% within 8h [37]. 

Zeolite membranes are not the only kind of membranes that have been used in pervaporation, organic and other types of inorganic membranes, different from zeolites, have been employed. Polymeric membranes of PVA (polyvinyMcohol) have been widely employed for dehydratation and separation of organic mixmres however, their main limitations are related to their low thermal and chemical stability. When the water content in the feed mixmre is high, polymeric membranes suffer from swelling moreover, in the separation of organic mixtures they usually present a low selectivity. 

The inorganic silica membranes, also commercial, have solved the problem of thermal and chemical stability however, these membranes are only used for dehydration purposes, leaving the problem of separation of organic mixtures unsolved. As we have seen previously, due to the versatility and special feamres of zeolites, new applications in pervaporation that are not possible with other membranes could be developed with zeolite membranes. GaUego-Lizon et al. [110] compared different types of commercial available membranes zeolite NaA from SMART Chemical Company Ltd., sUica (PERVAP SMS) and polymeric (PERVAP 2202 and PERVAP 2510) both from Sulzer Chemtech GmbH, for the pervaporation of water/f-butanol mixtures. The highest water flux was obtained with the silica membrane (3.5 kg/m h) while the zeolite membrane exhibited the highest selectivity (16,000). 

In general, most of the high-separation factors reported for zeolite membranes are associated with pervaporation processes (see Section 10.5) or with vapor-separation applications where the permeated component is preferentially adsorbed. This has given rise to a variety of works in which the membranes have been used for equilibrium displacement by selective product permeation. The largest group probably corresponds to esterification processes, where hydrophilic zeolite membranes are employed to remove the product, water, replacing the extensively studied polymer membranes [187-192]. 

MasudaT, Otani S, Tsuji T, KitamuraM, andMukai SR. Preparation of hydrophilic and acid-proof silicalite-1 zeolite membrane and its application to selective separation of water from water solutions of concentrated acetic acid by pervaporation. Sep Purif Technol 2003 32(1-3) 181-189. 

Water can be removed from methanol by a membrane of polyvinyl alcohol cross-linked with polyacrylic acid, with a separation factor of 465.204 A polymeric hydrazone of 2,6-pyridinedialdehyde has been used to dehydrate azeotropes of water with n- and /-propyl alcohol, s- and tort butyl alcohol, and tetrahydrofuran.205 The Clostridium acetobutylicum which is used to produce 1-butanol, is inhibited by it. Pervaporation through a poly(dimethyl-siloxane) membrane filled with cyclodextrins, zeolites, or oleyl alcohol kept the concentration in the broth lower than 1% and removed the inhibition.206 Acetic acid can be dehydrated with separation factors of 807 for poly(4-methyl-l-pentene) grafted with 4-vinylpyridine,207 150 for polyvinyl alcohol cross-linked with glutaraldehyde,208 more than 1300 for a doped polyaniline film (4.1 g/m2h),209 125 for a nylon-polyacrylic acid membrane (5400 g/m2h), and 72 for a polysulfone.210 Pyridine can be dehydrated with a membrane of a copolymer of acrylonitrile and 4-styrenesulfonic acid to give more than 99% pyridine.211 A hydrophobic silicone rubber membrane removes acetone selectively from water. A hydrophilic cross-linked polyvinyl alcohol membrane removes water selectively from acetone. Both are more selective than distillation.212... 

Zeolite membranes and films have been employed to modify the surface of conventional chemical electrodes, or to conform different types of zeolite-based physical sensors [49]. In quartz crystal microbalances, zeolites are used to sense ethanol, NO, SO2 and water. Cantilever-based sensors can also be fabricated with zeolites as humidity sensors. The modification of the dielectric constant of zeolites by gas adsorption is also used in zeolite-coated interdigitaled capacitors for sensing n-butane, NH3, NO and CO. Finally, zeolite films can be used as barriers (for ethanol, alkanes,...) for increasing the selectivity of both semiconductor gas sensors (e.g. to CO, NO2, H2) and optical chemical sensors. 

According to a recent conference given by Prof. Kita [162], the classical synthesis method currently used by Mitsui allows to produce about 250 zeolite membranes per day. Both the LTA and T types (Na K) membranes are now commercial and more than 80 pervaporation and vapor permeation plants are operating in Japan for the dehydration of organic liquids [163]. A typical pervaporation system, similar to the one described in [8], is shown in Fig. 11. One of the most recent applications concerns the production of fuel ethanol from cellulosic biomass by a vapour permeation/ pervaporation combined process. The required heat is only 1 200 kcal per liter of product, i.e. half of that of the classical process. Mitsui has recently installed a bio-ethanol pilot plant based on tubular LTA membranes in Brazil (3 000 liters/day) and a plant with 30 000 liters/day has been erected in India. The operating temperature is 130 °C, the feed is 93 % ethanol, the permeate is water and the membrane selectivity is 10 000. 

MTBE synthesis from /-butanol and methanol in a membrane reactor has been reported by Salomon et al. [2.453]. Hydrophilic zeolite membranes (mordenite or NaA) were employed to selectively remove water from the reaction atmosphere during the gas-phase synthesis of MTBE. This reaction was carried out over a bed of Amberlyst 15 catalyst packed in the inside of a zeolite tubular membrane. Prior to reaction, the zeolite membranes were characterized by measuring their performance in the separation of the equilibrium mixture containing water, methanol, /-butanol, MTBE, and isobutene. The results obtained with zeolite membrane reactors were compared with those of a fixed-bed reactor (FBR) under the same operating conditions. MTBE yields obtained with the PBMR at 334 K reached 67.6 %, under conditions, where the equilibrium value without product removal (FBR) would be 60.9%. 

A common feature of all catalysis for F-T synthesis, whether they are cobalt or iron based, is that the catalytic activity is reduced due to the oxidation of active species. Under the typical reaction conditions, this oxidation may be caused by water, which is one of the primary products in the F-T process. On the other hand, at low partial pressure water can also help to increase the product quality by increasing the chain growth probability. Thus, in situ removing some of the water from the product and keeping the water pressure at an optimal value may improve the catalysis activity and promote the reaction rate. Zhu and coworkers [22] have evaluated the potential separation using NaA zeolite membrane to in situ removal of water Irom simulated F-T product stream. High selectivity for water removal from CO, H2 and CH4 were obtained. This result opened an opportunity for in situ water removal from F-T synthesis under the reaction conditions. 

Besides producing mixed-hydrocarbons (ultra-clean diesel), F-T process can also selectively produce mixed-alcohols (oxygenated fuel). The addition of mixed-alcohols into gasoline can effectively reduce HC and CO emissions. However, before directly used as fuels or blended with conventional fuels, the water content in the as-produced F-T mixed-alcohols must be reduced below 0.5wt.%. This dehydration step is essential but difficult since most of the contained alcohols form azeotropies with water. In our group, we studied the dehydration performance of microwave synthesized NaA zeolite membrane toward F-T produced mixed-alcohols [24, 25]. The membrane also showed excellent pervaporation performance toward dehydration of simulated F-T produced mixed-alcohols. The permeate consisted of only water and little methanol (< 10%) in aU the range of feed composition. This result confirmed that NaA zeolite membrane based pervaporation (or vapor permeation) process could be an effective technology for dehydration of F-T produced mixed-alcohols. 

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