Advancing Molecular Sieving via Å-Scale Pore Tuning in Bottom-Up Graphene Synthesis.

Porous graphene films are attractive as a gas separation membrane given that the selective layer can be just one atom thick, allowing high-flux separation. A favorable aspect of porous graphene is that the pore size, essentially gaps created by lattice defects, can be tuned. While this has been demonstrated for postsynthetic, top-down pore etching in graphene, it does not exist in the more scalable, bottom-up synthesis of porous graphene. Inspired by the mechanism of precipitation-based synthesis of porous graphene over catalytic nickel foil, we herein conceive an extremely simple way to tune the pore size. This is implemented by increasing the cooling rate by over 100-fold from -1 °C min-1 to over -5 °C s-1. Rapid cooling restricts carbon diffusion, resulting in a higher availability of dissolved carbon for precipitation, as evidenced by quantitative carbon-diffusion simulation, measurement of carbon concentration as a function of nickel depth, and imaging of the graphene nanostructure. The resulting enhanced grain (inter)growth reduces the effective pore size which leads to an increase of the H2/CH4 separation factor from 6.2 up to 53.3.

A Competitive Study Using Electrospinning and Phase Inversion to Prepare Polymeric Membranes for Oil Removal.

Polyacrylonitrile (PAN) is a popular polymer that can be made into membranes using various techniques, such as electrospinning and phase inversion. Electrospinning is a novel technique that produces nonwoven nanofiber-based membranes with highly tunable properties. In this research, electrospun PAN nanofiber membranes with various concentrations (10, 12, and 14% PAN/dimethylformamide (DMF)) were prepared and compared to PAN cast membranes prepared by the phase inversion technique. All of the prepared membranes were tested for oil removal in a cross-flow filtration system. A comparison between these membranes' surface morphology, topography, wettability, and porosity was presented and analyzed. The results showed that increasing the concentration of the PAN precursor solution increases surface roughness, hydrophilicity, and porosity and, consequently, enhances the membrane performance. However, the PAN cast membranes showed a lower water flux when the precursor solution concentration increased. In general, the electrospun PAN membranes performed better in terms of water flux and oil rejection than the cast PAN membranes. The electrospun 14% PAN/DMF membrane gave a water flux of 250 LMH and a rejection of 97% compared to the cast 14% PAN/DMF membrane, which showed a water flux of 117 LMH and 94% oil rejection. This is mainly because the nanofibrous membrane showed higher porosity, higher hydrophilicity, and higher surface roughness compared to the cast PAN membranes at the same polymer concentration. The porosity of the electrospun PAN membrane was 96%, while it was 58% for the cast 14% PAN/DMF membrane.

Role of Fe/Co Ratio in Dual Phase Ce0.8Gd0.2O2-δ-Fe3-xCoxO4 Composites for Oxygen Separation.

Dual-phase membranes are increasingly attracting attention as a solution for developing stable oxygen permeation membranes. Ce0.8Gd0.2O2-δ-Fe3-xCoxO4 (CGO-F(3-x)CxO) composites are one group of promising candidates. This study aims to understand the effect of the Fe/Co-ratio, i.e., x = 0, 1, 2, and 3 in Fe3-xCoxO4, on microstructure evolution and performance of the composite. The samples were prepared using the solid-state reactive sintering method (SSRS) to induce phase interactions, which determines the final composite microstructure. The Fe/Co ratio in the spinel structure was found to be a crucial factor in determining phase evolution, microstructure, and permeation of the material. Microstructure analysis showed that all iron-free composites had a dual-phase structure after sintering. In contrast, iron-containing composites formed additional phases with a spinel or garnet structure which likely contributed to electronic conductivity. The presence of both cations resulted in better performance than that of pure iron or cobalt oxides. This demonstrated that both types of cations were necessary to form a composite structure, which then allowed sufficient percolation of robust electronic and ionic conducting pathways. The maximum oxygen flux is jO2 = 0.16 and 0.11 mL/cm2·s at 1000 °C and 850 °C, respectively, of the 85CGO-FC2O composite, which is comparable oxygen permeation flux reported previously.

Performance evaluation of an industrial ceramic nanofiltration unit for wastewater treatment in oil production.

An industrial ceramic nanofiltration membrane (pore size 0.9 nm) was tested in a Canadian oil field for more than 12,500 h to treat wastewater directly from daily operations, without any type of pre-treatment. This wastewater contained a high content of total suspended solids (13 to 510 mg/kg), and total organic carbon (31 to 134 mg/kg). The membrane unit was operated at different transmembrane pressure (TMP) set points (4-16 bar) and recovery set points (40-80%). The data show that ion and compound rejection depend strongly on a combination of both TMP and recovery, with the largest rejection occurring at low recovery values and high TMP values. Two mechanisms were responsible for rejection: sieving, which mostly impacted compound rejection, and electrostatic phenomena that impacted ion rejection. It is shown that ion rejection depends linearly on charge density of the ion. Ion rejection was measured as high as 85% and compounds (such as TSS) were rejected as high as 100%. The specific flux varied between 1-10 L/(m2.h.bar). Results from this field testing indicate the possibility of using these types of ceramic membranes for oil field wastewater treatment.

New Method toward a Robust Covalently Attached Cross-Linked Nanofiltration Membrane.

As nanofiltration applications increase in diversity, there is a need for new fabrication methods to prepare chemically and thermally stable membranes with high retention performance. In this work, thio-bromo "click" chemistry was adapted for the fabrication of a robust covalently attached and ultrathin nanofiltration membrane. The selective layer was formed on a pre-functionalized porous ceramic surface via a novel, liquid-vapor interfacial polymerization method. Compared to the most common conventional interfacial polymerization procedure, no harmful solvents and a minimal amount of reagents were used. The properties of the membrane selective layer and its free-standing equivalent were characterized by complementary physicochemical analysis. The stability of the thin selective layer was established in water, ethanol, non-polar solvents, and up to 150 °C. The potential as a nanofiltration membrane was confirmed through solvent permeability tests (water, ethanol, hexane, and toluene), PEG-in-water molecular weight cut-off measurements (≈700 g mol-1), and dye retention measurements.

Surfactant-dependent critical interfacial tension in silicon carbide membranes for produced water treatment.

During fossil oil extraction, a complex water stream known as produced water (PW), is co-extracted. Membrane treatment makes PW re-use possible, but fouling and oil permeation remain major challenges. In this work, membrane fouling and oil retention of Synthetic PW stabilized with a cationic, anionic, zwitterionic or nonionic surfactant, were studied at various surfactant and salt concentrations. We discuss our results in the framework of the Young-Laplace (YL) equation, which predicts for a given membrane, pressure and oil-membrane contact angle, a critical interfacial tension (IFT) below which oil permeation should occur. We observe such a transition from high to low oil retention with decreasing IFT for the anionic (SDS), cationic (CTAB) and non-ionic (TX) surfactant, but at significantly higher critical IFTs than predicted by YL. On the other side, for the zwitterionic DDAPS we do not observe a drop in oil retention, even at the lowest IFT. The discrepancy between our findings and the critical IFT predicted by YL can be explained by the difference between the measured contact angle and the effective contact angle at the wall of the membrane pores. This leads to a surfactant-dependent critical IFT. Additionally, our results point out that zwitterionic surfactants even at the lowest IFT did not present a critical IFT and exhibited low fouling and low oil permeation.

Melamine-Based Microporous Organic Framework Thin Films on an Alumina Membrane for High-Flux Organic Solvent Nanofiltration.

Microporous polymer frameworks have attracted considerable attention to make novel separation layers owing to their highly porous structure, high permeability, and excellent molecular separation. This study concerns the fabrication and properties of thin melamine-based microporous polymer networks with a layer thickness of around 400 nm, supported on an α-alumina support and their potential use in organic solvent nanofiltration. The modified membranes show excellent solvent purification performances, such as n-heptane permeability as high as 9.2 L m-2 h-1 bar -1 in combination with a very high rejection of approximately 99 % for organic dyes with molecular weight of ≥457 Da. These values are higher than for the majority of the state-of-the-art membranes. The membranes further exhibit outstanding long-term operation stability. This work significantly expands the possibilities of using ceramic membranes in organic solvent nanofiltration.

Triple-Layer Nanofiber Membranes for Treating High Salinity Brines Using Direct Contact Membrane Distillation.

A composite, three-layered membrane for membrane distillation was prepared from electrospun polyvinylidene fluoride (PVDF) nanofibers supported by commercial polyethersulfone (PES) nanofiber based nonwoven from E.I. duPont de Nemours company (DuPont). The membranes were tested in direct contact membrane distillation (DCMD) using a 5.0 M sodium chloride brine as a feed solution. The triple layer membrane combines the hydrophobicity of PVDF and the robustness of the PES. The triple layer membrane demonstrated excellent performance in DCMD (i.e., relatively high water flux compared to the commercial PVDF membrane and a complete salt rejection of the brine) with mechanical properties imparted by the PES layer. This work is the first to demonstrate the use of a commercially produced nanofiber nonwoven for membrane distillation.

New Generation of Mesoporous Silica Membranes Prepared by a Stöber-Solution Pore-Growth Approach.

Membranes consisting of uniform and vertically organized mesopores are promising systems for molecular filtration because of the possibility to combine high-flux and high-rejection properties. In this work, a new generation of mesoporous silica membranes (MSMs) have been developed, in which an organized mesoporous layer is directly formed on top of a porous ceramic support via a Stöber-solution pore-growth approach. Relevant characterization methods have been used to demonstrate the growth of the membrane separation layer and the effect of reaction time and the concentration of the reactants on the microstructure of the membrane. Compared to previous studies using the evaporation-induced self-assembly method to prepare MSMs, an important increase in water permeability was observed (from 1.0 to at least 3.8 L m-2 h-1 bar-1), indicating an improved pore alignment. The water permeability, cyclohexane permporometry tests, and molecular cut-off measurements (MWCO ≈ 2300 Da) were consistent with membranes composed of 2-3 nm accessible pores.

MIL-53(Al) and NH2-MIL-53(Al) modified α-alumina membranes for efficient adsorption of dyes from organic solvents.

To the best of our knowledge, for the first time MIL-53(Al) and NH2-MIL-53(Al) modified α-alumina membranes are investigated for the adsorption of organic dyes from organic solvents. These new, modified membranes show excellent adsorption of high concentrations of Rose Bengal dye in methanol and isopropanol solutions.

One-Pot Synthesis of High-Flux b-Oriented MFI Zeolite Membranes for Xe Recovery.

We demonstrate that b-oriented MFI (Mobil Five) zeolite membranes can be manufactured by in situ crystallization using an intermediate amorphous SiO2 layer. The improved in-plane growth by using a zeolite growth modifier leads to fusion of independent crystals and eliminates boundary gaps, giving good selectivity in the separation of CO2/Xe mixtures. The fast diffusion of CO2 dominates the overall membrane selectivity toward the CO2/Xe mixture. Because of the straight and short [010] channels, the obtained CO2 permeation fluxes are several orders of magnitude higher than those of carbon molecular sieving membranes and polymeric membranes, opening opportunities for Xe recovery from waste anesthetic gas.

Sorption Behavior of Compressed CO2 and CH4 on Ultrathin Hybrid Poly(POSS-imide) Layers.

Sorption of compressed gases into thin polymeric films is essential for applications including gas sensors and membrane based gas separation. For glassy polymers, the sorption behavior is dependent on the nonequilibrium status of the polymer. The uptake of molecules by a polymer is generally accompanied by dilation, or swelling, of the polymer material. In turn, this dilation can result in penetrant induced plasticization and physical aging that affect the nonequilibrium status of the polymer. Here, we investigate the dilation and sorption behavior of ultrathin membrane layers of a hybrid inorganic-organic network material that consists of alternating polyhedral oligomeric silsesquioxane and imide groups, upon exposure to compressed carbon dioxide and methane. The imide precursor contains fluoroalkene groups that provide affinity toward carbon dioxide, while the octa-functionalized silsesquioxane provides a high degree of cross-linking. This combination allows for extremely high sorption capacities, while structural rearrangements of the network are hindered. We study the simultaneous uptake of gases and dilation of the thin films at high pressures using spectroscopic ellipsometry measurements. Ellipsometry provides the changes in both the refractive index and the film thickness, and allows for accurate quantification of sorption and swelling. In contrast, gravimetric and volumetric measurements only provide a single parameter; this does not allow an accurate correction for, for instance, the changes in buoyancy because of the extensive geometrical changes of highly swelling films. The sorption behavior of the ultrathin hybrid layers depends on the fluoroalkene group content. At low pressure, the apparent molar volume of the gases is low compared to the liquid molar volume of carbon dioxide and methane, respectively. At high gas concentrations in the polymer film, the apparent molar volume of carbon dioxide and methane exceeds that of the liquid molar volume, and approaches that of the gas phase. The high sorption capacity and reversible dilation characteristics of the presented materials provide new directions for applications including gas sensors and gas separation membranes.

Formation and prevention of fractures in sol-gel-derived thin films.

Sol-gel-derived thin films play an important role as the functional coatings for various applications that require crack-free films to fully function. However, the fast drying process of a standard sol-gel coating often induces mechanical stresses, which may fracture the thin films. An experimental study on the crack formation in sol-gel-derived silica and organosilica ultrathin (submicron) films is presented. The relationships among the crack density, inter-crack spacing, and film thickness were investigated by combining direct micrograph analysis with spectroscopic ellipsometry. It is found that silica thin films are more prone to fracturing than organosilica films and have a critical film thickness of 300 nm, above which the film fractures. In contrast, the organosilica films can be formed without cracks in the experimentally explored regime of film thickness up to at least 1250 nm. These results confirm that ultrathin organosilica coatings are a robust silica substitute for a wide range of applications.

Synthesis of porous inorganic hollow fibers without harmful solvents.

A route for the fabrication of porous inorganic hollow fibers with high surface-area-to-volume ratio that avoids harmful solvents is presented. The approach is based on bio-ionic gelation of an aqueous mixture of inorganic particles and sodium alginate during wet spinning. In a subsequent thermal treatment, the bio-organic material is removed and the inorganic particles are sintered. The method is applicable to the fabrication of various inorganic fibers, including metals and ceramics. The route completely avoids the use of organic solvents, such as N-methyl-2-pyrrolidone, and additives associated with the currently used fiber fabrication methods. In addition, it inherently avoids the manifestation of so-called macro voids and allows the facile incorporation of additional metal oxides in the inorganic hollow fibers.

Kinetic analysis of the thermal processing of silica and organosilica.

The incorporation of an organic group into sol-gel-derived silica causes significant changes in the structure and properties of these materials. Therefore, the thermal treatment of organosilica materials may require a different approach. In the present paper, kinetic parameters (activation energy, pre-exponential constant, and reaction models) have been determined from mass loss data for the dehydration, dehydroxylation, and decomposition reactions that take place upon heating silica and organosilica. Parameters were obtained by employing model-free isoconversional methods to data obtained under multiple heating rates as well as by multivariate analysis of the kinetics using a multistep reaction model with distributed activation energy. For silica, it can be concluded that the reaction atmosphere (i.e., inert or thermo-oxidative) has no influence on the reaction rate of the dehydration and dehydroxylation reactions that are responsible for the densification of the material. Under inert atmosphere, full dehydration can be reached without affecting the organic moiety. Achieving complete dehydroxylation of the organosilica is practically impossible as decomposition does manifest itself under commonly employed calcination temperatures. This indicates that prudence is required in designing a heat treatment program for these hybrid materials. To aid in optimizing the thermal treatment, a predictive model was developed, which can be used to forecast the extent of dehydration, dehydroxylation, and decomposition reactions under a multitude of temperature programs.

Sieving of hot gases by hyper-cross-linked nanoscale-hybrid membranes.

Macromolecular networks consisting of homogeneously distributed covalently bonded inorganic and organic precursors are anticipated to show remarkable characteristics, distinct from those of the individual constituents. A novel hyper-cross-linked ultrathin membrane is presented, consisting of a giant molecular network of alternating polyhedral oligomeric silsesquioxanes and aromatic imide bridges. The hybrid characteristics of the membrane are manifested in excellent gas separation performance at elevated temperatures, providing a new and key enabling technology for many important industrial scale applications.