Publications Details
Dual-Layer Asymmetric Microporous Silica Membranes
We report a novel sol-gel dip-coating process to form dual-layer microporous silica membranes with improved membrane performance and reproducibility. First, we deposit a surfactant-templated silica (STS) intermediate layer on top of a commercial {gamma}-alumina support both to improve its ''surface finish'' and to prevent a subsequently deposited microporous overlayer from penetrating into the support. Second, membranes are processed under clean room conditions to avoid dust contamination and, third, membranes are vacuum-calcined to promote further pore shrinkage and impart surface hydrophobicity. The resulting asymmetric membrane exhibits a gradual change in pore diameter from 50{angstrom} ({gamma}-alumina support layer) to 10-12{angstrom} (STS intermediate layer), and then to 3-4{angstrom} (30nm thick, ultramicroporous silica top-layer). Compared to a single-layer process using only the microporous overlayer, the dual-layer process improves both flux and selectivity. For the industrially important problem of natural gas purification, the combined CO{sub 2} flux [(3{approx} 0.5) x 10{sup {minus}4} cm{sup 3}(STP)/(s{center_dot}cm{sup 2}{center_dot}cm-Hg)] and CO{sub 2}/CH{sub 4} separation factors [200{approx}600] are superior to all previously reported values for separation of a 50/50 (v/v) CO{sub 2}/CH{sub 4} gas mixture. In addition, the membrane selectively separated hydrogen from a simulated reformate from partial oxidation of methanol as evidenced by a high concentration of hydrogen recovery.