Mixed matrix membrane with super water washed silica containing molecular sieves and methods for making and using the same
First Claim
1. A method for preparing silica containing molecular sieves which may be mixed with an organic polymer to create a mixed matrix membrane, the method comprising:
- water washing silica containing molecular sieves sufficiently to produce water washed molecular sieves which are substantially free of surface remnants, such that when the water washed molecular sieves are subjected to a Sieve Wash Conductivity Test, a wash filtrate is produced having a conductivity of less than 110 micro mhos/cm.
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Abstract
The present invention provides a method for preparing silica containing molecular sieves which may be mixed with an organic polymer to create a mixed matrix membrane. Further, this invention includes a method of making such a mixed matrix membrane and the membrane itself. A process for separating component gases from a mixture using the subject mixed matrix membrane is also described. The method for preparing silica containing molecular sieves comprises super water washing silica containing molecular sieves to produce water washed molecular sieves which are substantially free of surface remnants. Super water washing also ideally lowers the concentration of alkali metals in the molecular sieves. The water washed sieves are sufficiently free of surface remnants such that when the water washed sieves are subjected to a Sieve Wash Conductivity Test, a wash filtrate is produced having a conductivity of less than 110 micro mhos/cm, more preferably less than 80 micro mhos/cm, even more preferably less than 50 micro mhos/cm, and most preferably less than 30 micro mhos/cm. It is believed that super washing the sieves to this degree will enhance, compared to conventional preparation techniques, the ability of the molecular sieves to bond with an organic polymer to form a highly selective and permeable mixed matrix membrane.
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Citations
23 Claims
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1. A method for preparing silica containing molecular sieves which may be mixed with an organic polymer to create a mixed matrix membrane, the method comprising:
water washing silica containing molecular sieves sufficiently to produce water washed molecular sieves which are substantially free of surface remnants, such that when the water washed molecular sieves are subjected to a Sieve Wash Conductivity Test, a wash filtrate is produced having a conductivity of less than 110 micro mhos/cm. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10)
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11. A mixed matrix membrane comprising:
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a continuous phase organic polymer and water washed silica containing molecular sieves which are dispersed throughout the polymer;
wherein the water washed silica containing molecular sieves are sufficiently water washed to remove surface remnants prior to being dispersed into the organic polymer such that if the water washed silica containing molecular sieves are subjected to a Sieve Wash Conductivity Test, a wash filtrate is produced having a conductivity of less than 110 micro mhos/cm. - View Dependent Claims (12, 13, 14, 15)
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16. A method of making a mixed matrix membrane, the method comprising the steps of:
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water washing silica containing molecular sieves sufficiently to produce water washed molecular sieves which are substantially free of surface remnants, such that when the water washed molecular sieves are subjected to a Sieve Wash Conductivity Test, a wash filtrate is produced having a conductivity of less than 110 micro mhos/cm;
dispersing the water washed molecular sieves into a solvated organic polymer; and
allowing the organic polymer to dry thereby creating a mixed matrix membrane comprising an organic polymer with the water washed molecular sieves dispersed therein. - View Dependent Claims (17, 18, 19)
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20. A process for separating component gases of a gas mixture comprising the steps of:
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providing a mixed matrix membrane comprising molecular sieves dispersed in a continuous phase of a polymer in which the sieves have been sufficiently super water washed prior to being incorporated into the continuous phase to be substantially free of surface remnants, such that when the water washed molecular sieves are subjected to a Sieve Wash Conductivity Test, a wash filtrate is produced having a conductivity of less than 110 micro mhos/cm;
contacting a gas mixture, including component gases, on one side of the membrane to cause the component gases to selectively permeate the membrane; and
removing from the opposite side of the membrane a permeate gas composition enriched in concentration in at least one of the component gases. - View Dependent Claims (21, 22, 23)
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Specification