Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01D—SEPARATION
  • B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
  • B01D53/22—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols by diffusion
  • B01D53/228—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols by diffusion characterised by specific membranes
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01D—SEPARATION
  • B01D67/00—Processes specially adapted for manufacturing semi-permeable membranes for separation processes or apparatus
  • B01D67/0039—Inorganic membrane manufacture
  • B01D67/0048—Inorganic membrane manufacture by sol-gel transition
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  • B01D67/00—Processes specially adapted for manufacturing semi-permeable membranes for separation processes or apparatus
  • B01D67/0081—After-treatment of organic or inorganic membranes
  • B01D67/0083—Thermal after-treatment
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  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01D—SEPARATION
  • B01D67/00—Processes specially adapted for manufacturing semi-permeable membranes for separation processes or apparatus
  • B01D67/0081—After-treatment of organic or inorganic membranes
  • B01D67/0088—Physical treatment with compounds, e.g. swelling, coating or impregnation
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  • B01D69/00—Semi-permeable membranes for separation processes or apparatus characterised by their form, structure or properties; Manufacturing processes specially adapted therefor
  • B01D69/10—Supported membranes; Membrane supports
  • B01D69/105—Support pretreatment
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  • B01D69/00—Semi-permeable membranes for separation processes or apparatus characterised by their form, structure or properties; Manufacturing processes specially adapted therefor
  • B01D69/14—Dynamic membranes
  • B01D69/141—Heterogeneous membranes, e.g. containing dispersed material; Mixed matrix membranes
  • B01D69/1411—Heterogeneous membranes, e.g. containing dispersed material; Mixed matrix membranes containing dispersed material in a continuous matrix
  • B01D69/14111—Heterogeneous membranes, e.g. containing dispersed material; Mixed matrix membranes containing dispersed material in a continuous matrix with nanoscale dispersed material, e.g. nanoparticles
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  • B01D—SEPARATION
  • B01D71/00—Semi-permeable membranes for separation processes or apparatus characterised by the material; Manufacturing processes specially adapted therefor
  • B01D71/02—Inorganic material
  • B01D71/024—Oxides
  • B01D71/027—Silicium oxide
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  • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
  • C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
  • C04B35/14—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on silica
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  • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
  • C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
  • C04B35/624—Sol-gel processing
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  • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
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  • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
  • C04B41/45—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
  • C04B41/50—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements with inorganic materials
  • C04B41/5025—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements with inorganic materials with ceramic materials
  • C04B41/5035—Silica
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  • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
  • C04B41/45—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
  • C04B41/52—Multiple coating or impregnating multiple coating or impregnating with the same composition or with compositions only differing in the concentration of the constituents, is classified as single coating or impregnation
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  • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
  • C04B41/80—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone of only ceramics
  • C04B41/81—Coating or impregnation
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  • C04B41/87—Ceramics
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  • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
  • C04B41/80—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone of only ceramics
  • C04B41/81—Coating or impregnation
  • C04B41/89—Coating or impregnation for obtaining at least two superposed coatings having different compositions
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01D—SEPARATION
  • B01D2323/00—Details relating to membrane preparation
  • B01D2323/48—Influencing the pH
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  • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
  • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
  • C04B2111/00793—Uses not provided for elsewhere in C04B2111/00 as filters or diaphragms
  • C04B2111/00801—Membranes; Diaphragms
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  • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
  • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
  • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
  • C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
  • C04B2235/3217—Aluminum oxide or oxide forming salts thereof, e.g. bauxite, alpha-alumina
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  • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
  • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
  • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
  • C04B2235/34—Non-metal oxides, non-metal mixed oxides, or salts thereof that form the non-metal oxides upon heating, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
  • C04B2235/3409—Boron oxide, borates, boric acids, or oxide forming salts thereof, e.g. borax
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  • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
  • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
  • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
  • C04B2235/44—Metal salt constituents or additives chosen for the nature of the anions, e.g. hydrides or acetylacetonate
  • C04B2235/441—Alkoxides, e.g. methoxide, tert-butoxide

Definitions

• Gas separation membranes containing a silica-based microporous silica layer doped with a trivalent element a silica-based microporous silica layer doped with a trivalent element.
• the present invention relates to ceramic membranes, which are particularly suitable for gas separation by molecular sieving. More specifically, the invention relates to a method for depositing on a porous support a microporous layer based on amorphous silica substantially free of defects and stable at high temperature, thus giving access to membranes capable of ensuring effective separation of gas such as He or H 2 at temperatures of the order of 300 to 500 ° C.
• Gas separation by membranes is a technique widely used by the chemical industry, which has been particularly developed over the last 25 years.
• membrane used polymer, ceramic, dense or porous
• Molecular sieving is a technique that consists of separating gases present in mixture, using a difference in kinetic radius of the molecules to be separated.
• a microporous membrane is used which, under the effect of a difference in concentration or of partial pressure on either side of the membrane, allows the molecules with the smallest kinetic radius to diffuse preferentially and retains more the molecules of higher size.
• the membrane is used as molecular sieve, implementing a steric exclusion process ("pore size exclusion"), which inhibits or delays the diffusion of large molecules, thus promoting the diffusion of size the weakest.
• pore size exclusion a steric exclusion process
• adsorption phenomena on the surface of the membrane and / or in its pores
• the aforementioned transmembrane gas separation technique is very advantageous, especially insofar as it is modular and can be used in a continuous mode.
• this technique has, in practice, many fields of application.
• it is used for the separation of O 2 and N 2 from air, for the extraction of H 2 and N 2 in NH 3 production gases, or of H 2 in effluents with hydrocarbon base such as those resulting from refining processes, or else to remove CO 2 or NO in various gaseous effluents.
• the first parameter (i) is expressed by the "permeance" of the membrane, namely the amount of gas that the membrane allows to diffuse per unit area and time as a function of the applied pressure (expressed in mol.m- 2 . s "1 .Pa " 1 ).
• the second parameter (ii) is in turn reflected by the "selectivity" of the membrane, which is calculated by the ratio (in moles) of the quantity of small molecules (whose diffusion is sought) on the quantity of molecules. larger size (supposed to be retained) that are contained in the gas mixture that allows the membrane to diffuse.
• Membranes having a high separation efficiency in terms of permeance and selectivity are all the more difficult to obtain as the hydrodynamic diameter of the gases to be separated is small.
• the gas separation technique is particularly delicate when it is desired to carry out a separation of helium (kinetic diameter less than 0.30 nm) or of gas having similar kinetic diameters, such as H 2 or H 2 O , or their deuterated or tritiated equivalents.
• membranes comprising a separation layer having pores of extremely small dimensions, general less than 1 nm, and this in sufficient number to allow to obtain good permeation.
• Membranes of this type are currently known, including layers having a pore diameter of less than 1 nm.
• membranes of this type there may be mentioned membranes comprising a dense or microporous layer, such as a microporous layer based on silica (generally called MMS layer for the English “molecular sieve silica”).
• These membranes including a silica-based microporous layer are generally obtained by depositing a film of a silica sol on a porous support (for example an alumina-based support), then thermally treating the resulting film to convert it to a ceramic layer of microporous silica.
• the silica sol used in this context is generally obtained according to the so-called "sol-gel” technique, namely by hydrolyzing a silicon alkoxide, typically a tetraalkoxysilane such as TEOS (tetraethoxysilane, of formula Si (OEt) 4 ).
• a major problem encountered with membranes including silica-based microporous layers of the aforementioned type is their propensity for the presence of defects, which affect the selectivity of the membrane. These defects are mainly related to the rigidity of the silica network, which is a source of crack formation when the layer is subjected to stresses (which is particularly the case with membranes of large size necessary for gas separations at high temperatures. industrial scale) and / or when it is deposited on a support having surface irregularities (which is almost always the case).
• the cracks thus formed considerably affect the selectivity of the membrane, insofar as, rather than through the pores, the gases preferentially diffuse at the level of the cracks, which are of a nature to let species of greater kinetic diameter spread than the species to be separated.
• a solution that has been proposed to limit the phenomena of cracking in microporous layers of silica obtained by the sol-gel route consists in replacing all or part of the tetraalkoxysilanes used as precursors of the silica with alkoxysilanes carrying less than 4 reactive groups of silica. alkoxy type.
• MTES methyltriethoxysilane
• the microporous layer is to be used at high temperature, in particular at temperatures above 200 ° C., and more particularly at temperatures above 250 ° C.
• the microporous layers of silica which are obtained from alkyltrialkoxysilanes of type MTES specifically contain alkyl groups within their structure. Under the effect of an increase in temperature in the abovementioned ranges, these groups oxidize and are extracted with CO 2 starting, which induces the appearance of additional porosity in the layer, generally associated with embrittlement. this layer, likely to induce cracking. These different phenomena are detrimental to the selectivity of the gas separation.
• membranes based on a layer obtained from MTES are generally not suitable for effective separation of helium or H 2 at temperatures of the order of 300 0 C to 500 0 C, in particular under pressure.
• An object of the present invention is to provide a novel method for accessing gas separation membranes capable of separating helium or hydrogen at a temperature greater than 200 ° C., in particular at temperatures of the order of 300 to 500 0 C, and with a permeance and a selectivity preferably at least as good, and advantageously greater than those currently known separation membranes.
• the invention aims in particular to provide membranes having such properties of permeance and selectivity without having to implement the specific method described in US 2004/00380044.
• the subject of the present invention is a process for preparing a gas separation membrane, comprising the deposition of a film of a silica sol on a porous support, and then the heat treatment of the film thus deposited, characterized in that the silica sol which is deposited as a film on the porous support is prepared by hydrolyzing a silicon alkoxide in the presence of a doping amount of a precursor of an oxide of a trivalent element, this precursor being for example an alkoxide or an acid of the trivalent element.
• trivalent element is meant, in the sense of the present description, here an element whose atoms are capable of being inserted into the silica network with a degree of crosslinking at most equal to 3.
• the trivalent element used according to the present invention is boron (B). Boron is generally used as the only trivalent element. However, the boron may alternatively be used in admixture with other trivalent elements, for example aluminum.
• oxide precursor of a trivalent element denotes, within the meaning of the present description, a compound which is capable of forming an oxide based on the trivalent element under the conditions of hydrolysis of the alkoxide of silicon, which, in the method of the invention, allows to incorporate the trivalent element in the silica network during its formation.
• the precursor used for this purpose is an alkoxide of the trivalent element.
• the process of the present invention consists in preparing the membrane according to a conventional sol-gel technique, but by specifically performing the hydrolysis of the silicon alkoxide with the additional presence of a precursor an oxide of a trivalent element.
• the trivalent element alkoxide used is generally introduced into the hydrolysis medium of the silicon alkoxide in the form of at least one compound corresponding to the following formula (I):
• M denotes boron (B).
• the 3 R groups are identical or different (generally identical), and each represents a hydrocarbon chain comprising from 1 to 8 carbon atoms, preferably an alkyl group, preferably containing from 2 to 4 carbon atoms.
• the trivalent element alkoxide used can be formed in situ in the medium of the hydrolysis of the silicon alkoxide.
• boron oxide B 2 O 3 and an alcohol of formula ROH, where R has the abovementioned meaning can be introduced into the medium of the hydrolysis of the silicon alkoxide, whereby the oxide Boron and alcohol react in situ to form a boron alkoxide boron precursor, capable of leading to the incorporation of boron into the forming silica matrix.
• alumina Al 2 O 3 can be introduced together with an alcohol ROH, to form in situ an aluminum alkoxide precursor allowing the incorporation of aluminum into the silica matrix in formation.
• trivalent elemental oxide As a precursor of trivalent elemental oxide, it is also possible to introduce into the hydrolysis medium of silicon alkoxide an acid of the trivalent element, for example at least one compound having the following formula (I 1 ) :
• alkoxide-type trivalent element oxide precursor includes such an acid.
• the trivalent element used according to the invention is introduced into the silica-forming medium in a doping amount.
• silica generally remains the major constituent in the deposited silica layer.
• the oxide precursor of the trivalent element is most often introduced into the silica-forming medium with a trivalent element / silicon molar ratio of less than 1: 1 (100%), and most often less than at 1: 2, this ratio generally being greater than 1: 100 (1%).
• this ratio is most often advantageous for this ratio to be at least 1: 20 (5%), more preferably at least 1: 10 ( 10%), for example at least 1: 5 (20%).
• the molar ratio (trivalent element / silicon) in the silica-forming medium may advantageously be between 1% and 50%, typically between 5% and 40%, for example between 10% and 30%.
• the report molar (boron / silicon) in the silica forming medium is advantageously included in the above-mentioned terminal.
• this high selectivity of separation can be achieved with very small thicknesses of the silica layer, which allows to obtain at the same time very high permeances for gases such as hydrogen or helium.
• the process of the invention leads to permeation membranes making it possible to obtain highly efficient separations of gases such as He or H 2 at high temperature, with permeances that can reach values of the order of 10 -6 mol. .r ⁇ 2 .s "1 .Pa" 1.
• these benefits appear to be due at least in part to the introduction of the trivalent element in the silica network produced a decrease its degree of crosslinking and, consequently, a decrease in its rigidity, similar to that observed at low temperature using the alkyltrialkoxysilanes of the MTES type, but unlike the case of these alkyltrialkoxysilanes, the solution proposed in the context of the present invention does not imply the introduction of organic species within the silica network, which pyrolyze at high temperature by affecting the properties of the membrane, in particular by creating porosity.
• the method of the invention provides similar advantages to those obtained with the use of alkyltrialcoxysilanes type MTES, but allowing further implementation of the membrane at higher temperatures. It should be noted in this regard that the method of the invention is generally implemented in using tetraalkoxysilanes of the TEOS type, excluding silanes bearing non-reactive groups of alkyltrialkoxysilane type.
• boron is generally known as a vitrifying element, and it would therefore rather expected that its incorporation into the silica induces a decrease in the thermal stability of the ceramic microporous layer, detrimental to the separation of gases such that He or H 2 .
• the process of the invention can be carried out by implementing the currently known processes for depositing silica layers on porous supports using the sol-gel process, provided that it also introduces a precursor of an oxide of a trivalent element in the hydrolysis medium of the silicon alkoxide, so as to dope the silica formed by said trivalent element.
• the process of the invention comprises the following successive steps: (A) according to the sol-gel technique, a silica sol doped with said trivalent element is produced by hydrolyzing a silicon alkoxide (typically TEOS) in an aqueous medium, generally hydro-alcoholic, containing a doping amount of a precursor of an oxide of the trivalent element; (B) the soil thus prepared is deposited on a porous support; and
• a silicon alkoxide typically TEOS
• aqueous medium generally hydro-alcoholic, containing a doping amount of a precursor of an oxide of the trivalent element
• the deposited film is thermally treated, whereby it is converted into a microporous silica-based ceramic layer doped with the trivalent element.
• Step (A) for preparing the doped silica sol can be carried out under conditions known per se for the preparation of such sols.
• this This step is carried out by reacting the silicon alkoxide and the trivalent element oxide precursor in a hydroalcoholic medium at a pH suitable for the hydrolysis of these two compounds.
• This step (A) is carried out in an acid medium, typically at a pH of less than 2, preferably less than 1. This pH range is advantageously obtained by introducing into the medium a strong mineral acid such as nitric acid or hydrochloric acid.
• Step (A) is also advantageously carried out under conditions which initially allow the solubilization of the various reagents in the presence.
• step (A) is most often carried out in a hydro-alcoholic medium, preferably containing an alcohol selected from methanol, ethanol or propanol.
• the mass ratio water / alcohol is typically between 1: 5 and 5: 1, for example between 1: 3 and 3: 1.
• an alkoxide of the element trivalent, especially a boron alkoxide, as an oxide precursor it is particularly advantageous to use as alcohol an alcohol having substantially the same carbon number as the chains carried by the alkoxide, which makes it possible in particular to optimize the solubilization of the alkoxide.
• use is advantageously an alkoxide (I) of formula M (OR) 3 as defined above, and an alcohol of formula ROH, with identical R groups in the alcohol and the alkoxide (I).
• the concentration of silicon alkoxide is typically between 0.3 and 4 mol / L, this concentration being advantageously less than 3 mol / L, preferably less than 2 mol / L.
• this concentration is at least equal to 0.5 mol / L, which makes it possible in particular to facilitate the heat treatment step (C).
• step (A) is advantageously carried out by introducing boron oxide B 2 O 3 (typically in powder form) into a medium hydro-alcoholic (advantageously based on ethanol) containing a silicon alkoxide (generally a tetraalkoxysilane, for example TEOS) and brought to a pH below 2, typically less than 1.
• a silicon alkoxide generally a tetraalkoxysilane, for example TEOS
• B 2 O 3 introduced is converted in situ to boron alkoxide, which is then engaged with the silicon alkoxide in the hydrolysis and condensation reactions, whereby an acid boron-doped silica sol is obtained within its network.
• the reaction is preferably conducted at a temperature above 15 ° C, for example between 20 and 50 ° C., typically at a temperature below 40 ° C., which makes it possible to optimize the initial conversion of the boron oxide to alkoxide, so as to obtain an effective incorporation of boron in the silica network, rather than physical inclusions of B 2 O 3 in the structure of the silica.
• step (A) leads to the formation of a doped silica sol having a viscosity allowing deposition in the form of a film on a porous support in step (B) .
• This viscosity can be modulated by varying the duration and temperature of soil formation, gelation and viscosity increasing with aging time and with temperature.
• the technique used for the deposition of the film of step (B) depends on the nature of the porous support on which said film is to be deposited.
• the support may in particular be planar or tubular.
• the deposition of step (B) is generally carried out according to the so-called “spin coating” technique.
• the deposit of step (B) is rather carried out according to the so-called “slip casting” method.
• step (B) A very simple way to perform the deposition of step (B) is to immerse the porous support in the doped silica sol.
• this embodiment leads, surprisingly, to a particularly effective anchoring of the silica layer on the porous support.
• the immersion of the support in the soil makes it possible to substantially eliminate the presence of gas between the porous support and the silica layer being formed, which makes it possible to inhibit the phenomena of separation of the silica layer which are observed during the heat treatment of step (C) when the air remains present in the pores of the porous support.
• the porous support used in step (B) may be any porous support suitable for the preparation of gas separation membranes.
• the deposition of step (B) is carried out on a support comprising a porous alumina on the surface where the deposition is carried out.
• the support of step (B) comprises an alpha-alumina-based sub-layer (generally of a thickness of a few tens or hundreds of microns), on which a surface layer is deposited.
• gamma alumina generally a mesoporous layer having a thickness of the order of a few microns intended to receive the microporous layer based on doped silica deposited according to the invention.
• step (B) of the process (and, more generally, any step of depositing the silica sol doped on a porous support) can be optimized, for improve the cohesion of the silica layer doped on the porous support.
• the work carried out by the inventors shows that it is particularly advantageous to perform a pretreatment of the support prior to step (B), so as to increase its affinity for the deposited film.
• step (A-bis) it is particularly advantageous to conduct, prior to step (B), a step (A-bis) of pretreatment of the surface of the support to give it surface charges opposite to those of the doped silica of the soil used. in the film deposited in step (B).
• this step (A-bis) of pretreatment of the surface will typically be carried out by a base, typically ammonia (which will be removed during the treatment thermal step (C)).
• a basic sol it is preferable to treat the support with an acid, advantageously removable in step (C), typically hydrochloric or nitric acid.
• step (A-bis) is typically performed by immersion.
• step (A-bis) prior to step (B) can typically be carried out by impregnating the alumina-based support with an aqueous solution having a pH greater than the isoelectric point of the alumina. Since this isoelectric point is generally of the order of 9, the pH of the alumina-based surface treatment solution is advantageously greater than 10, for example between 10, typically of the order of 10.5.
• the process of the invention advantageously comprises, prior to the deposition of the film of step (B), a step (A-ter) of pre-impregnation of the porous support with the silica sol prepared by the step (A), followed by a surface rinsing of the support, and then a heat treatment of the thus rinsed support.
• step (A-ter) is advantageously carried out by totally immersing the porous support in the silica sol, which allows a particularly effective impregnation of the pores of the support.
• step (A-ter) By carrying out the above-mentioned step (A-ter), during the subsequent heat treatment of step (C), not only a doped silica-based surface layer, but a layer mechanically anchored in the pores is obtained. porous support, which prevents the phenomena of peeling of the silica layer.
• Pre-impregnation according to step (A-ter) is particularly effective with mesoporous supports, namely comprising pores with dimensions typically between 2 and 50 nm.
• the method of the invention comprises both the steps (A-bis) and (A-ter) above.
• step (A-bis) is preferably carried out before step (A-ter).
• the thermal pretreatment of the support is typically carried out at a temperature greater than 500 ° C., for example of the order of 600 ° C.
• Step (B) of the process of the invention is advantageously followed by a step of drying the film deposited on the support prior to step (C), which in particular makes it possible to further improve the cohesion between the deposited silica layer. and the support.
• This drying is generally carried out leaving the liquid film deposited on the support for 5 to 15 hours, typically 6 to 10 hours, at a temperature advantageously between 60 and 70 ° C., typically at a temperature of about 65.degree. ° C.
• step (C) of the process of the invention is a heat treatment which makes it possible to convert the film deposited in step (B) into a ceramic microporous layer based on doped silica.
• This heat treatment step can be carried out under the usual conditions used for the preparation of gas separation membranes. Typically, this heat treatment is carried out at a temperature of 300 to 600 ° C., generally above 400 ° C. (for example, between 500 and 600 ° C.) for a duration of a few hours (typically of the order of 2 hours).
• the heat treatment with low rise and fall in temperature, typically of the order of 0 , 1 to 5 0 C per minute, preferably less than 2 ° C per minute, for example between 0.5 and 1.5 ° C per minute, and typically of the order of 1 0 C per minute.
• a membrane adapted to the separation of gases comprising a microporous layer of silica doped with a trivalent element deposited on a porous support.
• Membranes of this type obtainable according to the process of the invention, constitute a particular object of the present invention.
• the process of the present invention gives access to original membranes, comprising a microporous layer of silica doped with boron, deposited on a microporous support.
• Such membranes have, to the knowledge of the inventors, never been described, and they constitute, as such, another object of the present invention.
• the microporous layer based on doped silica present in the membranes of the present invention is generally a thin layer having a thickness of between 50 and 500 nm, typically between 100 and 300 nm.
• the method of the invention also makes it possible to obtain microporous layers based on doped silica that are free from defects, even when the support used has a large size.
• the microporous layer based on doped silica present in the membranes of the invention is most often essentially (or exclusively) constituted by said doped silica, with the exception of other compounds or functional groups.
• the doped silica-based microporous layer of the membranes of the invention is generally free of organic groups of the type of those observed in the silica layers obtained by the sol-gel processes using alkyltrialkoxysilanes such as methyltriethoxysilane.
• the doped silica-based microporous layer present in the membranes of the present invention contains pores less than 1 nm in size.
• a doped silica sol where the silica is dispersed in the form of suspended objects (particles or particle aggregates) having hydrodynamic diameters less than 10 nm.
• the conditions to be used in step (A) to obtain such sols are illustrated in the examples below.
• the membranes of the invention advantageously comprise their silica layer doped on an alumina-based support of the type described above in the present description. Most often, this silica layer is a surface layer of the membrane. However, for certain particular applications, the silica layer deposited according to the process of the invention may be subsequently covered by another porous or quasi-dense layer (or several others), for example by a coating layer based on carbide silicon, allowing for example to perform a water separation.
• the membranes of the invention may contain several successive doped silica layers, typically obtained by repeating steps (A), (B) and (C).
• the membranes of the invention are particularly suitable for the separation of gases, and in particular for the separation of helium or hydrogen in gaseous mixtures comprising them, and in particular at higher temperatures. at 250 ° C., for example at temperatures of the order of 300 to 500 ° C., generally with transmembrane pressures of less than 8 bar.
• This specific application is another object of the present invention.
• the membranes of the invention comprise the microporous layer of doped silica deposited on a plane support.
• they are suitable for providing gas separation in the form of filters separating two cavities.
• they are advantageously in the form of plates or disks.
• the membranes of the invention comprise the microporous layer of doped silica deposited on the internal or external surface of a cylindrical support. These membranes are suitable for gas separation in a continuous mode.
• the membranes where the microporous layer of doped silica is deposited on the inner surface of the cylindrical support are generally used by circulating a gaseous mixture containing the gases to be extracted in the internal space of the cylinder, with a partial pressure of the gases to be extracted more important in this internal space than outside the cylinder. According to this mode, it is possible, for example, to purify a gaseous stream of helium or hydrogen containing impurities, helium or hydrogen being discharged from the cylinder and the impurities remaining trapped therein.
• the membranes comprising the microporous silica layer doped on the outer surface of the cylindrical support are rather intended to be used by circulating the gaseous mixture containing the gases to be extracted outside the cylinder and circulating in the internal space of the cylinder a stream of gases to be extracted with a reduced partial pressure relative to the outside.
• the gases to be extracted are entrained in the cylinder while the gases to be separated remain outside the cylinder.
• This mode is particularly suitable for extracting gases present in small amounts in a gas stream (hydrogen in hydrocarbon effluents for example).
• the membranes of the invention in particular those in which the doped silica-based microporous layer contains pores less than 1 nm in size, are particularly suitable for the separation of helium or hydrogen from a mixture comprising them. .
• membranes of this type are well suited to the removal of impurities in helium currents.
• the membranes of the invention find particularly useful application in the treatment of hot helium currents used in particular in the primary circuit of high-temperature nuclear reactors of new generation, so-called HTR.
• impurities such as CO, CO 2 or CHU. as well as Xe or Kr type fission products, which are present in the helium must be eliminated, insofar as they are a source of corrosion.
• the membranes of the invention make it possible to perform a such separation effectively, at working temperatures of helium in the reactor (between 300 and 500 0 C and under pressure).
• membranes in which the microporous layer of doped silica deposited on the surface of a cylindrical support, preferably on the inner surface, the membranes of the invention then making it possible to perform such a separation. in a continuous mode and in an efficient and quantitative manner, with permeances of up to values of the order of 10 -6 mol.m.sup.- 2 .sup.- 1 .Pa.sup.- 1 , and helium separation selectivities particularly high.
• the membranes of the invention find applications in many fields of use, given their multiple advantages.
• the membranes of the invention can be used to extract hydrogen hydrogen from gaseous mixtures containing it, such as effluents from petrochemical refineries, or to eliminate gaseous pollutants present in a stream of hydrogen, for example prior to its introduction into a synthesis reactor, or even into fuel cells (in particular of the PEM type) where they allow, among other things, to eliminate the CO type gases that can poison the catalysts.
• gaseous mixtures containing it such as effluents from petrochemical refineries
• gaseous pollutants present in a stream of hydrogen for example prior to its introduction into a synthesis reactor, or even into fuel cells (in particular of the PEM type) where they allow, among other things, to eliminate the CO type gases that can poison the catalysts.
• the membranes of the invention also lead to very good selectivities in the context of such hydrogen separation processes.
• the membranes of the invention can be used in many other fields where gas separation is required. inasmuch as they constitute very interesting improvements of the currently known membranes.
• the membranes of the invention are potentially usable for the separation of hydrogen and gases having a kinetic diameter greater than 0.30 mm, such as nitrogen, oxygen, carbonated gases (especially gases hydrocarbon), or even H2S.
• a membrane based on a microporous layer of silica doped with boron deposited on an alumina support was prepared under the following conditions:
• the alumina support used in this example is a carrier based on alumina marketed by PALL EXEKIA in the form of a hollow cylinder (internal diameter: 7 mm, outer diameter: 10 mm, length: 25 cm) comprising an inner layer based on mesoporous gamma-alumina (pore diameter: 5 nm) deposited on alpha alumina constituting the outside of the cylinder.
• This support was pretreated thermally at 600 ° C. (or 550 ° C.) according to the following profile: temperature rise at 1 ° C./min up to 600 ° C., hold for 2 hours at 600 ° C., temperature decrease to room temperature at 1 ° C / min.
• the support resulting from the preceding stage was completely immersed in the acidic soil (S) for 2 hours and then the support thus treated was rinsed with ethanol.
• the support was then dried by leaving it in an oven at 65 ° C for 8 hours.
• the support was heat-treated at 550 ° C. according to the following profile: rise in temperature at 1 ° C./min, hold at 550 ° C. for 2 hours, decrease in temperature at 1 ° C./min.
• the pretreated support from the previous steps was immersed completely in the soil (S) diluted with alcohol at 1/6 of its initial concentration for 2 hours.
• the support was then removed from the soil and allowed to dry in an oven at 65 ° C for 15 hours.
• the support covered by the film was heat-treated under the following conditions: - rise in temperature from 20 ° C. to 100 ° C., at a rate of 1 ° C. per minute;
• This membrane was tested by carrying out a separation of helium at 300 ° C. from a helium-based mixture containing 1% of CO 2 and 1% of CH 4 under the following conditions:
• a membrane based on a microporous double layer of silica doped with boron, deposited on an alumina support was prepared under the following conditions:
• the alumina support used in this example is a carrier based on alumina marketed by PALL EXEKIA in the form of a hollow cylinder (internal diameter: 7 mm, outer diameter: 10 mm, length: 25 cm) comprising an inner layer based on mesoporous gamma-alumina (pore diameter: 5 nm) deposited on alpha alumina constituting the outside of the cylinder.
• the support was first thermally pretreated to "open" the pores of the alumina. This treatment was carried out at 600 ° C. (or even 550 ° C.) according to the following profile: rise in temperature at 1 ° C./min up to 600 ° C., hold for 2 hours at 600 ° C., lowering temperature to temperature ambient at 1 ° C / min.
• the support was immersed in an aqueous ammonia solution of pH equal to 10.5, for 30 minutes, and then drained.
• the support was then immersed in silica / alumina sol (S Si / Al ) obtained by mixing:
• the support was heat-treated at 550 ° C. according to the following profile: rise in temperature at 1 ° C./min, hold at 550 ° C. for 2 hours, decrease in temperature at 1 ° C./min.
• the support was again immersed in an aqueous solution of ammonia with a pH of 10.5 for 30 minutes and then drained. The support was then completely immersed for 2 hours in the acidic soil (S) described in Example 1, and the support thus treated was rinsed with ethanol.
• the support was then dried by leaving it in an oven at 65 ° C for 8 to 12 hours. Following this drying, the support was heat-treated at 550 ° C. according to the following profile: rise in temperature at 1 ° C./min, hold at 550 ° C. for 2 hours, decrease in temperature at 1 ° C./min.
• the support was dried in an oven at 65 ° C for 8 to 12 hours in a vertical position, then subjected to heat treatment at 550 0 C (temperature rise at 1 ° C / min, holding at 550 ° C for 2 hours, lowering temperature to 1 ° C / min).
• the coated support thus obtained was immersed completely, firstly for 3 minutes in ethanol, then secondly in the soil (S), diluted with alcohol at 1/12 of its initial concentration, for 2 hours. Following this new immersion, the support was again dried in an oven at 65 ° C for 12 hours in a vertical position, then subjected to a heat treatment at 550 0 C (temperature rise at 1 ° C / min, maintenance at 550 0 C for 2 hours, lowering temperature to 1 ° C / min).

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