Review Of Historical Membrane Workshop Results

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Review of HistoricalMembrane WorkshopResultsSharon RobinsonOak Ridge National LaboratoryMembrane Technology WorkshopDOE Advanced Manufacturing OfficeChicago, ILJuly 24, 2012

Previous Membrane R&D Needs Studies Workshop reports and documents developed for DOE OIT/ITP/AMO tosupport the Technology Vision2020: The Chemical Industry (1996) asrequested by the White House Office of Science and Technology Policy– Separation Technologies for the IOF (1998)– Vision2020: 2000 Separations Roadmap (1999)– Materials for Separations Technologies: Energy and Emission ReductionOpportunities (2004)– Hybrid Separations/Distillation Technology: Research Opportunities for Energy andEmissions Reduction (2005)– Separation Technology R&D Needs for Hydrogen Production in the Chemical andPetrochemical Industries (2005)– Alternative, Renewable and Novel Feedstock for Producing Chemicals (2007)– Industrial Feedstock Flexibility Workshop Results (2009)2Managed by UT-Battellefor the U.S. Department of Energy

General Status of MembraneDevelopment for Industrial Applications Significant investment in membrane technology has occurred butwith limited industrial implementation– NETL development of ceramic membranes with applications in fuel cells, H2separations, and O2 separations– Significant R&D investment in palladium membranes for H2 recovery Major high energy industrial applications covered by OIT/ITP/AMO– Alternatives to distillation– Gas separations, primarily H2 and O2– Feedstock flexibility for chemical/petroleum industry Membrane systems needed for many high-energy industrialapplications are limited by lack of selectivity, narrow range ofuseful operating conditions (thermal stability and low permeation),and high costs3Managed by UT-Battellefor the U.S. Department of Energy

Major Barriers to MembraneDevelopment for Industrial ApplicationsImportant Properties for EmergingMembrane Systems Permeability Selectivity Durability (compaction) Resistance to fouling/fouling control Thermal stability Transport properties Defects, particularly at large scale Erosion/corrosion resistance Clean-in-place Advanced control systems Module design and scale-up Costs, particularly for high volumeapplications4Managed by UT-Battellefor the U.S. Department of Energy

Membrane Systems for DistillationApplicationsStatus Systems lack selectivity, have narrow range of operating conditions, and have high costs Higher selectivity/flux membranes that can withstand high temperatures (80 – 1,200 F);aggressive chemicals and organic mixtures with molecular sieving capabilities are needed– Organic membranes are not likely to withstand high distillation temperatures. Inorganicmaterials or inorganic/polymer composites have the highest potential, and hybrid systems maybe easier to implement than total replacement of distillation equipment New module configuration designs, fouling control, and advanced control systems areneeded to increase efficiency and reduce costs. Membranes are likely to be most successful in “clean” applications, i.e. gas recoveryGeneral R&D Opportunity Areas Pilot plant demonstrations of existing materials in specific applicationsModel Predictive Control (MPC) for membrane processMaterial compatibility studies for entire systems (not just membrane materials)Improved membrane chemical stabilityBetter scaling to reduce costs5Managed by UT-Battellefor the U.S. Department of Energy

Membrane Systems for DistillationApplications continuedR&D Opportunities for Specific Membrane Systems Inorganic metal membranes––––Refinement of the fabrication process to reduce defects in large scale membranesDurability and reliability testing of the membranesErosion and corrosion resistance of membranes under long-term test conditionsDevelopment of thin inorganic membrane films which will exhibit high fluxes Ceramic membranes– Develop materials that can operate with high selectivity and flux (a challenge forseparation of large molecules and similar size molecules)High Potential Application Areas Azeotrope breaking (CO2 / C2H6 separation) Pre-concentrator for distillation Bulk gas separations for low-temperature streams where existing polymers could beapplicable Vent gas recovery for refining and olefin/paraffin separations Desalination/reverse osmosis for phosphoric acid and caustic applications6Managed by UT-Battellefor the U.S. Department of Energy

Membranes for Gas SeparationsStatus Systems lack selectivity, have narrow range of operatingconditions, and have high costs Most promising membrane systems for these applications aremicroporous metal and ceramic membranesR&D Opportunities for Specific Membrane Materials Microporous metal and ceramic membranes– Refinement of fabrication process to reduce defects in largescale membranes– Development of higher flux/high temperature membranes– Development of metal oxide membrane materials capable ofoperation at 1100 F– Improved thermal mechanical performance7Managed by UT-Battellefor the U.S. Department of Energy

Membranes for Gas Separations continuedGeneral R&D Opportunity Areas High temperature membranes that are selective only to O2 or H2 Low temperature O2 selective membranes with permeance 100 x 10-8mole(s m2 Pa) High integrity H2 selective mixed matrix membranes Organic-inorganic hybrid membrane materials Improved H2 selective inorganic microporous membranesHigh Potential Energy Savings Application Areas H2 recovery in petroleum refining processes, such as catalytic crackingand hydroforming O2 enrichment for oxygen-fueled furnaces (reducing the mass of nitrogenby 50%)8Managed by UT-Battellefor the U.S. Department of Energy

Membrane Systems for FeedstockFlexibility ApplicationsStatus Workshops have focused on feedstock flexibility for the chemical andpetroleum industries: alternative bio-based feedstocks, alternative fossilbased feedstocks, and improvements in efficiency for conventionalfeedstocks Membranes are needed that can withstand processing conditions(temperatures, pH, chemicals); can cope with fouling; can selectivelyseparate desired materials from dilute solutions; have improvedpermeance, selectivity, reduced costs, chemical resistance; are defect freeat large scale; and have proven performance at scaleGeneral R&D Opportunity Areas Design better molecule configuration in membranes for fouling abatement Develop facilitated transport membranes to separate like molecules Develop membrane adsorbent materials (ionic liquids, olid polymeric) Develop smart membranes and separations systems for low concentration /high value products9Managed by UT-Battellefor the U.S. Department of Energy

Membrane Systems for FeedstockFlexibility continuedR&D Opportunities for Specific Systems Membranes to support bio-based feedstocks– Membranes to increase alcohol yield, separate salts, and purifysolvents– Scalable, low-cost commercially available membranes– Membranes that withstand the bio-processing conditions(temperatures, pH, chemicals), can cope with bio-system fouling, andcan selectively separate desired materials from dilute solutions Membranes to support alternative fossil-fuel feedstocks– Improved air separations Membranes to support improvements in conventional feedstocks– Replace conventional distillation– Improved gas separations10 Managed by UT-Battellefor the U.S. Department of Energy

Summary from Previous Workshops Significant investment in membrane technology has occurredbut with limited industrial implementation The major R&D needs are for improved selectivity, range ofuseful operating conditions, defect-free scale-up for largevolume systems, module configuration designs, fouling control,advanced control systems, and lower costs– Inorganic materials or inorganic/polymer composites have the highestpotential for success for many of these applications Research programs should focus on these technical areas forthe most promising high energy applications11 Managed by UT-Battellefor the U.S. Department of Energy

General Status of Membrane Development for Industrial Applications Significant investment in membrane technology has occurred but with limited industrial implementation –NETL development of ceramic membranes with applications in fuel cells, H 2 separations, and O 2 separations –Significant R&D investment in palladium membranes for H 2 .

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