WO2016148988A1 - High selectivity epoxysilicone-cross-linked polyimide membranes for gas separations - Google Patents

High selectivity epoxysilicone-cross-linked polyimide membranes for gas separations Download PDF

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WO2016148988A1
WO2016148988A1 PCT/US2016/021439 US2016021439W WO2016148988A1 WO 2016148988 A1 WO2016148988 A1 WO 2016148988A1 US 2016021439 W US2016021439 W US 2016021439W WO 2016148988 A1 WO2016148988 A1 WO 2016148988A1
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membrane
epoxysilicone
cross
group
mixtures
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Chunqing Liu
Howie Q. TRAN
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Honeywell UOP LLC
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UOP LLC
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D69/00—Semi-permeable membranes for separation processes or apparatus characterised by their form, structure or properties; Manufacturing processes specially adapted therefor
    • B01D69/12—Composite membranes; Ultra-thin membranes
    • B01D69/125—In situ manufacturing by polymerisation, polycondensation, cross-linking or chemical reaction
    • 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
    • B01D69/00—Semi-permeable membranes for separation processes or apparatus characterised by their form, structure or properties; Manufacturing processes specially adapted therefor
    • B01D69/02—Semi-permeable membranes for separation processes or apparatus characterised by their form, structure or properties; Manufacturing processes specially adapted therefor characterised by their properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D69/00—Semi-permeable membranes for separation processes or apparatus characterised by their form, structure or properties; Manufacturing processes specially adapted therefor
    • B01D69/08—Hollow fibre membranes
    • B01D69/087—Details relating to the spinning process
    • B01D69/088—Co-extrusion; Co-spinning
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D69/00—Semi-permeable membranes for separation processes or apparatus characterised by their form, structure or properties; Manufacturing processes specially adapted therefor
    • B01D69/12—Composite membranes; Ultra-thin membranes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D71/00—Semi-permeable membranes for separation processes or apparatus characterised by the material; Manufacturing processes specially adapted therefor
    • B01D71/06—Organic material
    • B01D71/58—Other polymers having nitrogen in the main chain, with or without oxygen or carbon only
    • B01D71/62—Polycondensates having nitrogen-containing heterocyclic rings in the main chain
    • B01D71/64—Polyimides; Polyamide-imides; Polyester-imides; Polyamide acids or similar polyimide precursors
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D71/00—Semi-permeable membranes for separation processes or apparatus characterised by the material; Manufacturing processes specially adapted therefor
    • B01D71/06—Organic material
    • B01D71/70—Polymers having silicon in the main chain, with or without sulfur, nitrogen, oxygen or carbon only
    • 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
    • B01D2053/221—Devices
    • B01D2053/223—Devices with hollow tubes
    • B01D2053/224—Devices with hollow tubes with hollow fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2256/00—Main component in the product gas stream after treatment
    • B01D2256/10—Nitrogen
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2256/00—Main component in the product gas stream after treatment
    • B01D2256/12—Oxygen
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2256/00—Main component in the product gas stream after treatment
    • B01D2256/16—Hydrogen
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2256/00—Main component in the product gas stream after treatment
    • B01D2256/18—Noble gases
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2256/00—Main component in the product gas stream after treatment
    • B01D2256/24—Hydrocarbons
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2257/00—Components to be removed
    • B01D2257/10—Single element gases other than halogens
    • B01D2257/108—Hydrogen
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2257/00—Components to be removed
    • B01D2257/10—Single element gases other than halogens
    • B01D2257/11—Noble gases
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2257/00—Components to be removed
    • B01D2257/30—Sulfur compounds
    • B01D2257/304—Hydrogen sulfide
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2257/00—Components to be removed
    • B01D2257/50—Carbon oxides
    • B01D2257/504—Carbon dioxide
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2257/00—Components to be removed
    • B01D2257/70—Organic compounds not provided for in groups B01D2257/00 - B01D2257/602
    • B01D2257/702—Hydrocarbons
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2257/00—Components to be removed
    • B01D2257/70—Organic compounds not provided for in groups B01D2257/00 - B01D2257/602
    • B01D2257/708—Volatile organic compounds V.O.C.'s
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
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    • B01D2257/80—Water
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2323/00—Details relating to membrane preparation
    • B01D2323/30—Cross-linking
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D71/00—Semi-permeable membranes for separation processes or apparatus characterised by the material; Manufacturing processes specially adapted therefor
    • B01D71/06—Organic material
    • B01D71/66—Polymers having sulfur in the main chain, with or without nitrogen, oxygen or carbon only
    • B01D71/68—Polysulfones; Polyethersulfones
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02C—CAPTURE, STORAGE, SEQUESTRATION OR DISPOSAL OF GREENHOUSE GASES [GHG]
    • Y02C20/00—Capture or disposal of greenhouse gases
    • Y02C20/40—Capture or disposal of greenhouse gases of CO2

Definitions

  • This invention relates to a high selectivity epoxysilicone-cross-linked polyimide membrane comprising a polyimide polymer with hydroxyl functional groups cross-linked with epoxy functional groups on epoxysilicone polymer under UV radiation and methods for making and using the membrane.
  • Polymers provide a range of properties including low cost, permeability, mechanical stability, and ease of processability that are important for gas separation.
  • Glassy polymers i.e., polymers at temperatures below their Tg
  • Cellulose acetate (CA) glassy polymer membranes are used extensively in gas separation. Currently, such CA membranes are used for natural gas upgrading, including the removal of carbon dioxide.
  • CA membranes have many advantages, they are limited in a number of properties including selectivity, permeability, and in chemical, thermal, and mechanical stability.
  • the membranes most commonly used in commercial gas and liquid separation applications are asymmetric polymeric membranes and have a thin nonporous selective skin layer that performs the separation. Separation is based on a solution-diffusion mechanism. This mechanism involves molecular-scale interactions of the permeating gas with the membrane polymer. The mechanism assumes that in a membrane having two opposing surfaces, each component is sorbed by the membrane at one surface, transported by a gas concentration gradient, and desorbed at the opposing surface. According to this solution- diffusion model, the membrane performance in separating a given pair of gases (e.g.,
  • CO2/CH4, O2/N2, H2/CH4 is determined by two parameters: the permeability coefficient
  • permeability PA
  • OCA/B selectivity
  • PA permeability
  • OCA/B selectivity
  • PA the product of the gas flux and the selective skin layer thickness of the membrane, divided by the pressure difference across the membrane.
  • Gases can have high permeability coefficients because of a high solubility coefficient, a high diffusion coefficient, or because both coefficients are high. In general, the diffusion coefficient decreases while the solubility coefficient increases with an increase in the molecular size of the gas.
  • both high permeability and selectivity are desirable because higher permeability decreases the size of the membrane area required to treat a given volume of gas, thereby decreasing capital cost of membrane units, and because higher selectivity results in a higher purity product gas.
  • One of the components to be separated by a membrane must have a sufficiently high permeance at the preferred conditions or an extraordinarily large membrane surface area is required to allow separation of large amounts of gases or liquids.
  • Such membranes are characterized by a thin, dense, selectively semipermeable surface "skin” and a less dense void-containing (or porous), non-selective support region, with pore sizes ranging from large in the support region to very small proximate to the "skin".
  • fabrication of defect- free high selectivity asymmetric integrally skinned polyimide membranes is difficult.
  • the presence of nanopores or defects in the skin layer reduces the membrane selectivity.
  • the high shrinkage of the polyimide membrane on cloth substrate during membrane casting and drying process results in unsuccessful fabrication of asymmetric integrally skinned polyimide flat sheet membranes using phase inversion technique.
  • US 2005/0268783 Al disclosed chemically cross-linked polyimide hollow fiber membranes prepared from a monoesterified polymer followed by final cross-linking after hollow fiber formation.
  • US 7,485,173 disclosed UV cross-linked mixed matrix membranes via UV radiation.
  • the cross-linked mixed matrix membranes comprise microporous materials dispersed in the continuous UV cross-linked polymer matrix.
  • TFC thin film composite membrane
  • the TFC membrane has a layer of a blend of polyethersulfone and aromatic polyimide with a thickness from 0.1 to 3 microns.
  • US 8,337,598 disclosed a TFC hollow fiber membrane with a core player and a sheath UV-crosslinked polyimide polymer layer.
  • Integrally-skinned asymmetric membranes have a selective thin layer and a porous layer from the same membrane material and formed from the same membrane solution at the same time.
  • the present invention discloses a high selectivity epoxysilicone-cross-linked polyimide membrane comprising a polyimide polymer with hydroxyl functional groups cross-linked with epoxy functional groups on epoxysilicone polymer under UV radiation, methods for making the membrane, and the use of the membrane for natural gas upgrading and H 2 purification.
  • This invention pertains to a high selectivity epoxysilicone-cross-linked polyimide membrane comprising a polyimide polymer with hydroxyl functional groups cross-linked with epoxy functional groups on epoxysilicone polymer under UV radiation, methods for making the membrane, and the use of the membrane for natural gas upgrading and H 2 purification.
  • This invention pertains to a thin film composite membrane or an asymmetric integrally skinned membrane comprising a high selectivity epoxysilicone-cross-linked polyimide selective skin layer with hydroxyl functional groups on the polyimide polymer chain cross-linked with epoxy functional groups on epoxysilicone polymer chain under UV radiation.
  • the high selectivity epoxysilicone-cross-linked polyimide membrane can have either flat sheet or hollow fiber geometry.
  • the present invention provides a high selectivity epoxysilicone-cross-linked polyimide membrane.
  • the cross-linking between the polyimide polymer comprising hydroxyl functional groups and the epoxysilicone polymer comprising epoxy functional groups in the present invention provides the epoxysilicone-cross-linked polyimide membrane not only high selectivity, but also high plasticization and chemical resistance due to the formation of cross- linked polymer chain segments through possible direct covalent bonds.
  • the present invention provides a high selectivity epoxysilicone-cross-linked polyimide membrane comprising an epoxysilicone-cross-linked polyimide wherein the polyimide polymer with hydroxyl functional groups cross-linked with epoxy functional groups on epoxysilicone polymer.
  • the epoxysilicone-cross-linked polyimide polymer comprises a plurality of repeating units of formula (I), wherein formula (I) is
  • R is selected from the group consisting of
  • D B ((C 6 H 5 COO)(HO)(C6H9)(CH2)2)(CH3)Si02/2,
  • R is selected from the group consisting of hydrogen, methyl, and ethyl, and wherein j, k, 1, m, n, p, x, y, z, and u are positive integers andj, k, 1, n, p, u, and z may be zero;
  • Xi and X2 are selected from the group consisting of
  • Xi and X2 are the same or different from each other; wherein Y 1 is selected from the group consisting of
  • R' ' is selected from the group consisting of
  • R" ' is selected from the group consisting of -H, COCH3, and mixtures thereof;
  • Y2 is selected from the group consisting of
  • R" is selected from the group consisting of
  • R" ' is selected from the group consisting of -H, COCH3, and mixtures thereof; wherein a, b, and c are independent integers from 1 to 500.
  • Xi and X2 are selected from the group consisting of
  • Xi and X2 are the same or different from each other; preferably Yi is selected from the group consisting of
  • R" ' is selected from the group consisting of -H, COCH3, and mixtures thereof; preferably Y2 is
  • R is selected from the group consisting of MD x DEyM, MED x DEyME
  • R" ' is selected from the group consisting of -H, COCH 3 , and mixtures thereof.
  • the high selectivity epoxysilicone-cross-linked polyimide membrane in the present invention can be either asymmetric integrally skinned membrane or thin film composite (TFC) membrane.
  • the asymmetric integrally-skinned flat sheet or hollow fiber high selectivity epoxysilicone-cross-linked polyimide membrane in the present invention was prepared by a phase inversion process.
  • the membrane dope formulation for the preparation of the asymmetric integrally- skinned flat sheet or hollow fiber high selectivity epoxysilicone-cross-linked polyimide membrane in the present invention comprises good solvents for the polyimide polymer with hydroxyl functional groups in the present invention that can completely dissolve the polymer.
  • Representative good solvents for use in this invention include N-methylpyrrolidone (NMP), ⁇ , ⁇ -dimethyl acetamide (DMAC), methylene chloride, ⁇ , ⁇ -dimethylformamide (DMF), dimethyl sulfoxide (DMSO), dioxanes, 1,3-dioxolane, acetone, mixtures thereof, others known to those skilled in the art and mixtures thereof.
  • the membrane dope formulation for the preparation of asymmetric integrally-skinned flat sheet or hollow fiber high selectivity epoxysilicone-cross-linked polyimide membrane in the present invention also comprises poor solvents that cannot dissolve the polyimide polymer with hydroxyl functional groups such as methanol, ethanol, tetrahydrofuran (THF), toluene, n-octane, n-decane, lactic acid, citric acid, and mixtures thereof.
  • hydroxyl functional groups such as methanol, ethanol, tetrahydrofuran (THF), toluene, n-octane, n-decane, lactic acid, citric acid, and mixtures thereof.
  • the proper weight ratio of the solvents used in the present invention provides asymmetric integrally-skinned flat sheet or hollow fiber high selectivity epoxysilicone-cross-linked polyimide membrane with less than 200 nm super thin nonporous selective skin layer which results in high permeances.
  • the thin film composite high selectivity epoxysilicone-cross-linked polyimide membrane described in the current invention comprises a thin nonporous selective separation layer comprising epoxysilicone-cross-linked polyimide described in the present invention and a porous nonselective mechanical support layer made from a material different from the epoxysilicone-cross-linked polyimide described in the present invention.
  • the porous nonselective mechanical support layer made from a material different from the polyimide polymer with hydroxyl functional groups described in the present invention with a low selectivity and high flux can be made from materials including cellulose acetate, cellulose triacetate, polysulfone, polyethersulfone, polyamide, polyimide, polyetherimide,
  • polyurethane polycarbonate, polystyrene, polybenzoxazole, or mixtures thereof.
  • One epoxysilicone-cross-linked polyimide thin film composite hollow fiber membrane comprising an epoxysilicone-cross-linked polyimide described in the present invention is fabricated via a co-extrusion phase inversion spinning process from a sheath dope and a core dope using a triple-orifice spinneret.
  • the core dope comprises an
  • the sheath dope comprises a poly(2,2'-bis-(3,4- dicarboxyphenyl)hexafluoropropane dianhydride-3,3'-dihydroxy-4,4'-diamino-biphenyl-3,3'- diacetoxy-4,4'-diamino-biphenyl) (abbreviated as PI-A).
  • PI-A poly(2,2'-bis-(3,4- dicarboxyphenyl)hexafluoropropane dianhydride-3,3'-dihydroxy-4,4'-diamino-biphenyl-3,3'- diacetoxy-4,4'-diamino-biphenyl)
  • a bore fluid containing 20% by weight of water in MP was injected to the bore of the fiber simultaneously with the co-extruding of the core dope and sheath dope.
  • the ratio of the core dope flow rate and the sheath dope flow rate was controlled to be in a range of 3 : 1 to 10: 1.
  • the dried thin film composite hollow fiber membrane was further cross-linked with an UV curable epoxysilicone SilForce* UV9315 purchased from Momentive,
  • SilForce UV9380C is a trademark of Momentive Performance Materials, Inc.
  • the PI-A-ESi/P84-PES epoxysilicone-cross-linked polyimide thin film composite hollow fiber membrane showed high CO2/CH4 separation performance with CO2 permeance of 69 GPU and CO2/CH4 selectivity of 30.6 for CO2/CH4 separation at 50°C under 5617 kPa feed pressure with 10% CO2 and 90% CH4 in the feed gas.
  • the invention provides a process for separating at least one gas from a mixture of gases using the high selectivity epoxysilicone-cross-linked polyimide membrane comprising an epoxysilicone-cross-linked polyimide described herein, the process comprising: (a) providing a high selectivity epoxysilicone-cross-linked polyimide membrane described in the present invention which is permeable to said at least one gas; (b) contacting the mixture on one side of the high selectivity epoxysilicone-cross-linked polyimide membrane to cause said at least one gas to permeate the membrane; and (c) removing from the opposite side of the membrane a permeate gas composition comprising a portion of said at least one gas which permeated said membrane.
  • the high selectivity epoxysilicone-cross-linked polyimide membranes described in the current invention are not only suitable for CO2/CH4 separation, but also suitable for a variety of other gas separations such as H2 purification, O2 2 and H2S/CH4 separations.
  • gas separation membranes such as CA, polyimide, and polysulfone membranes formed by phase inversion and solvent exchange methods and with either hollow fiber or flat sheet geometry have an asymmetric integrally skinned membrane structure.
  • Such membranes are characterized by a thin, dense, selectively semipermeable surface skin layer and a less dense void-containing (or porous), non-selective support layer, with pore sizes ranging from large in the support region to very small proximate to the skin.
  • the skin layer and the porous non-selective support layer are formed from the same membrane material and formed from the same membrane solution at the same time.
  • TFC membranes are also characterized by a thin, selectively
  • the selective thin layer and the non-selective porous layer can be made from different materials.
  • the selective thin layer and the non-selective porous layer can be formed from two separate steps or from a co-extrusion process of two different membrane solutions.
  • the selective thin dense layer on the non-selective porous layer can be delaminated easily from the non-selective porous layer, which will result in significantly decreased selectivity for gas separations.
  • the sheath layer with a selective thin dense layer and relatively porous thin sublayer and the core non-selective porous layer are formed from a one-step phase inversion process. Therefore, the sheath layer cannot be delaminated easily from the non-selective core layer.
  • the core non-selective porous layer of the TFC hollow fiber membrane can be made from low cost membrane materials and the thin selective sheath layer can be made from high cost high performance new membrane material.
  • the present invention provides a high selectivity epoxysilicone-cross-linked polyimide membrane comprising a polyimide polymer with hydroxyl functional groups cross-linked with epoxy functional groups on epoxysilicone polymer in the presence of an effective amount of a bis(dodecylphenyl)iodonium salt photocatalyst under UV radiation.
  • This invention also pertains to the application of the high selectivity epoxysilicone-cross- linked polyimide membrane for 3 ⁇ 4 purifications such as H2/CH4 separation, and also for a variety of other gas separations such as separations of CO2/CH4, H2S/CH4, CO2/N2, olefin/paraffin (e.g. propylene/propane), and O2/N2 separations.
  • This invention pertains to a thin film composite membrane or an asymmetric integrally skinned membrane comprising a high selectivity epoxysilicone-cross-linked polyimide selective skin layer with hydroxyl functional groups on the polyimide polymer chain cross-linked with epoxy functional groups on epoxysilicone polymer chain in the presence of the bis(dodecylphenyl)iodonium salt photocatalyst under UV radiation.
  • the high selectivity epoxysilicone-cross-linked polyimide membrane can have either flat sheet or hollow fiber geometry.
  • the present invention provides a high selectivity epoxysilicone-cross-linked polyimide membrane.
  • the cross-linking between the polyimide polymer comprising hydroxyl functional groups and the epoxysilicone polymer comprising epoxy functional groups in the present invention provides the epoxysilicone-cross-linked polyimide membrane not only high selectivity, but also high plasticization and chemical resistance due to the formation of cross- linked polymer chain segments through possible direct covalent bonds.
  • the present invention provides a high selectivity epoxysilicone-cross-linked polyimide membrane comprising an epoxysilicone-cross-linked polyimide wherein the polyimide polymer with hydroxyl functional groups cross-linked with epoxy functional groups on epoxysilicone polymer.
  • the epoxysilicone-cross-linked polyimide polymer comprises a plurality of repeating units of formula (I), wherein formula (I) is
  • R is selected from the group consisting of
  • ⁇ ⁇ (CF 3 CH 2 CH 2 )(CH 3 ) Si0 2/2 ,
  • D B ((C 6 H 5 COO)(HO)(C 6 H 9 )(CH 2 ) 2 )(CH 3 )Si0 2/2 ,
  • R is selected from the group consisting of hydrogen, methyl, and ethyl, and wherein j, k, 1, m, n, p, x, y, z, and u are positive integers andj, k, 1, n, p, u, and z may be zero;
  • X 1 and X 2 are selected from the group consisting of
  • R" is selected from the group consisting of
  • R'" is selected from the group consisting of -H, COCH3, and mixtures thereof;
  • Y2 is selected from the roup consisting of
  • R" is selected from the group consisting of
  • R" ' is selected from the group consisting of -H, COCH3, and mixtures thereof; wherein a, b, and c are independent integers from 1 to 500.
  • Xi and X2 are selected from the group consisting of
  • Xi and X2 are the same or different from each other; preferably Yi is selected from the group consisting of
  • R" ' is selected from the group consisting of -H, COCH3, and mixtures thereof; preferably Y2 is preferably R is selected from the group consisting of MD x DEyM, MED x DEyME
  • Y 1 is selected from the group consisting of
  • R" ' is selected from the group consisting of -H, COCH3, and mixtures thereof.
  • the polyimide polymer with hydroxyl functional groups used for the preparation of the high selectivity epoxysilicone-cross-linked polyimide membrane in the present invention comprises a plurality of repeating units of formula (II), wherein formula (II) is
  • Xi and X2 are selected from the group consisting of
  • R" is selected from the group consisting of
  • R" ' is selected from the group consisting of -H, COCH3, and mixtures thereof;
  • Y2-OH is selected from the group consisting of
  • R" is selected from the group consisting of
  • R" ' is selected from the group consisting of -H, COCH3, and mixtures thereof; wherein a and b are independent integers from 1 to 500.
  • Xi and X2 are selected from the group consisting of
  • Xi and X2 are the same or different from each other; preferably Yi is selected from the group consisting of
  • R" ' is selected from the group consisting of -H, COCH3, and mixtures thereof; preferably Y2-OH is
  • Yi is selected from the group consisting of
  • R" ' is selected from the group consisting of -H, COCH3, and mixtures thereof.
  • the polyimide polymer with hydroxyl functional groups used for making the high selectivity epoxysilicone-cross-linked membrane described in the current invention is selected from poly(2,2'-bis-(3,4-dicarboxyphenyl)hexafluoropropane dianhydride-3,3'- dihydroxy-4,4'-diamino-biphenyl-3,3'-diacetoxy-4,4'-diamino-biphenyl) (abbreviated as PI- A), poly(2,2'-bis-(3,4-dicarboxyphenyl)hexafluoropropane dianhydride-3,3'-dihydroxy-4,4'- diamino-biphenyl-3,3'-diacetoxy-4,4'-diamino-biphenyl-3,5-diaminobenzoic acid)
  • PI-B (abbreviated as PI-B), and a mixture thereof.
  • the polyimide polymer with hydroxyl functional groups used for making the high selectivity epoxysilicone-cross-linked membrane described in the current invention have a weight average molecular weight in the range of 50,000 to 1,000,000 Daltons, preferably between 70,000 to 500,000 Daltons.
  • epoxysilicone polymer with epoxy functional groups used for the preparation of the high selectivity epoxysilicone-cross-linked polyimide membrane in the present invention is selected from the group consisting of
  • D B ((C 6 H 5 COO)(HO)(C 6 H 9 )(CH 2 ) 2 )(CH 3 )Si0 2/2 ,
  • R is selected from the group consisting of hydrogen, methyl, and ethyl, and wherein j, k, 1, m, n, p, x, y, z, and u are positive integers and j, k, 1, n, p, u, and z may be zero.
  • the epoxysilicone polymer with epoxy functional groups used for the preparation of the high selectivity epoxysilicone-cross-linked polyimide membrane in the present invention is selected from the group consisting of MD x D E y M, M E D x D E y M E , M E D x D E y M, and mixtures thereof; wherein
  • the epoxysilicone polymer with epoxy functional groups used for the preparation of the high selectivity epoxysilicone-cross-linked polyimide membrane in the present invention is selected from commercially available UV curable epoxysilicones, for example, Momentive SilForce* UV-photocurable epoxysilicones under the denominations of SilForce* UV9315, SilForce* UV9430, and SilForce* UV9400.
  • the bis(dodecylphenyl)iodonium salt photocatalyst used for the preparation of the high selectivity epoxysilicone-cross-linked polyimide membrane described in the present invention is selected from the salts of the group of acids consisting of hexafluoroantimonic acid, hexafluoroarsenic acid, hexafluorophosphoric acid, tetrafluoroboric acid,
  • iodonium photo- catalyst is the commercially available one from Momentive under the denominations of SilForce* UV9380C.
  • photocatalyst and the epoxysilicone polymer used for the preparation of the high selectivity epoxysilicone-cross-linked polyimide membrane in the present invention is in a range from 100: 1 to 100: 10 by weight.
  • the high selectivity epoxysilicone-cross-linked polyimide membrane in the present invention can be either asymmetric integrally skinned membrane or thin film composite (TFC) membrane.
  • the asymmetric integrally-skinned flat sheet or hollow fiber high selectivity epoxysilicone-cross-linked polyimide membrane in the present invention was prepared by a phase inversion process.
  • the membrane dope formulation for the preparation of the asymmetric integrally- skinned flat sheet or hollow fiber high selectivity epoxysilicone-cross-linked polyimide membrane in the present invention comprises good solvents for the polyimide polymer with hydroxyl functional groups in the present invention that can completely dissolve the polymer.
  • Representative good solvents for use in this invention include N-methylpyrrolidone (NMP), ⁇ , ⁇ -dimethyl acetamide (DMAC), methylene chloride, ⁇ , ⁇ -dimethylformamide (DMF), dimethyl sulfoxide (DMSO), dioxanes, 1,3-dioxolane, acetone, mixtures thereof, others known to those skilled in the art and mixtures thereof.
  • the membrane dope formulation for the preparation of asymmetric integrally-skinned flat sheet or hollow fiber high selectivity epoxysilicone-cross-linked polyimide membrane in the present invention also comprises poor solvents that cannot dissolve the polyimide polymer with hydroxyl functional groups such as methanol, ethanol, tetrahydrofuran (TFIF), toluene, n-octane, n-decane, lactic acid, citric acid, and mixtures thereof.
  • hydroxyl functional groups such as methanol, ethanol, tetrahydrofuran (TFIF), toluene, n-octane, n-decane, lactic acid, citric acid, and mixtures thereof.
  • the proper weight ratio of the solvents used in the present invention provides asymmetric integrally-skinned flat sheet or hollow fiber high selectivity epoxysilicone-cross-linked polyimide membrane with less than 200 nm super thin nonporous selective skin layer which results in high permeances.
  • the thin film composite high selectivity epoxysilicone-cross-linked polyimide membrane comprises a thin nonporous selective separation layer comprising epoxysilicone- cross-linked polyimide described in the present invention and a porous nonselective mechanical support layer made from a material different from the epoxysilicone-cross-linked polyimide described in the present invention.
  • the thin film composite high selectivity epoxysilicone-cross-linked polyimide membrane has either hollow fiber or flat sheet geometry.
  • the solution of the polyimide polymer with hydroxyl functional groups has a concentration of from 20 to 40 wt%.
  • the solution of the polyimide polymer with hydroxyl functional groups and the polymer solution for the formation of the porous nonselective mechanical support layer were co-extruded from a spinneret to form TFC hollow fiber high selectivity epoxysilicone-cross-linked polyimide membrane.
  • the porous nonselective mechanical support layer was made from a material different from the polyimide polymer with hydroxyl functional groups described in the present invention with a low selectivity and high flux. Selection of the porous nonselective mechanical support layer for the preparation of TFC high selectivity epoxysilicone-cross- linked polyimide membrane in the present invention may be made on the basis of the heat resistance, solvent resistance, and mechanical strength of the porous nonselective mechanical support layer, as well as other factors dictated by the operating conditions for selective permeation.
  • the porous nonselective mechanical support layer is preferably at least partially self-supporting, and in some instances may be essentially self-supporting.
  • the porous nonselective mechanical support layer may provide essentially all of the structural support for the membrane.
  • Some preferred polymers different from the polyimide polymer with hydroxyl functional groups described in the present invention that are suitable for the preparation of the porous nonselective mechanical support layer for the TFC high selectivity epoxysilicone- cross-linked polyimide membrane according to the present invention include, but are not limited to, polysulfones, sulfonated polysulfones, polyethersulfones (PESs), sulfonated PESs, polyethers, polyetherimides such as Ultem, cellulosic polymers such as cellulose acetate and cellulose triacetate, polyamides, polyimides such as P84 and P84HT, polyether ketones, and mixtures thereof.
  • the invention provides a process for separating at least one gas from a mixture of gases using high selectivity epoxysilicone-cross-linked polyimide membrane described in the present invention, the process comprising: (a) providing a high selectivity epoxysilicone- cross-linked polyimide membrane described in the present invention which is permeable to said at least one gas; (b) contacting the mixture on one side of the high selectivity
  • the high selectivity epoxysilicone-cross-linked polyimide membrane described in the present invention is especially useful in the purification, separation or adsorption of a particular species in the liquid or gas phase.
  • the high selectivity epoxysilicone-cross-linked polyimide membrane described in the present invention is especially useful in gas separation processes in air purification, petrochemical, refinery, and natural gas industries.
  • separations include separation of volatile organic compounds (such as toluene, xylene, and acetone) from an atmospheric gas, such as nitrogen or oxygen and nitrogen recovery from air.
  • Further examples of such separations are for the separation of C0 2 or H 2 S from natural gas, H 2 from N 2 , CH 4 , and Ar in ammonia purge gas streams, H 2 recovery in refineries, olefin/paraffin separations such as propylene/propane separation, and iso/normal paraffin separations.
  • any given pair or group of gases that differ in molecular size for example nitrogen and oxygen, carbon dioxide and methane, hydrogen and methane or carbon monoxide, helium and methane, can be separated using the high selectivity epoxysilicone-cross-linked polyimide membrane described in the present invention. More than two gases can be removed from a third gas.
  • some of the gas components which can be selectively removed from a raw natural gas using the membrane described herein include carbon dioxide, oxygen, nitrogen, water vapor, hydrogen sulfide, helium, and other trace gases.
  • Some of the gas components that can be selectively retained include hydrocarbon gases.
  • permeable components are acid components selected from the group consisting of carbon dioxide, hydrogen sulfide, and mixtures thereof and are removed from a hydrocarbon mixture such as natural gas
  • one module, or at least two in parallel service, or a series of modules may be utilized to remove the acid components.
  • the pressure of the feed gas may vary from 275 kPa to 2.6 MPa (25 to 4000 psi).
  • the differential pressure across the membrane can be as low as 70 kPa or as high as 14.5 MPa (10 psi or as high as 2100 psi) depending on many factors such as the particular membrane used, the flow rate of the inlet stream and the availability of a compressor to compress the permeate stream if such compression is desired.
  • Differential pressure greater than 14.5 MPa (2100 psi) may rupture the membrane.
  • a differential pressure of at least 0.7 MPa (100 psi) is preferred since lower differential pressures may require more modules, more time and compression of intermediate product streams.
  • the operating temperature of the process may vary depending upon the temperature of the feed stream and upon ambient temperature conditions.
  • the effective operating temperature of the membranes of the present invention will range from -50° to 150°C. More preferably, the effective operating temperature of the high selectivity epoxysilicone-cross-linked polyimide membrane of the present invention will range from -20° to 100°C, and most preferably, the effective operating temperature of the membranes of the present invention will range from 25° to 100°C.
  • the high selectivity epoxysilicone-cross-linked polyimide membrane described in the present invention are also especially useful in gas/vapor separation processes in chemical, petrochemical, pharmaceutical and allied industries for removing organic vapors from gas streams, e.g. in off-gas treatment for recovery of volatile organic compounds to meet clean air regulations, or within process streams in production plants so that valuable compounds (e.g., vinylchloride monomer, propylene) may be recovered.
  • gas/vapor separation processes in which the high selectivity epoxysilicone-cross-linked polyimide membrane described in the present invention may be used are hydrocarbon vapor separation from hydrogen in oil and gas refineries, for hydrocarbon dew pointing of natural gas (i.e. to decrease the hydrocarbon dew point to below the lowest possible export pipeline temperature so that liquid hydrocarbons do not separate in the pipeline), for control of methane number in fuel gas for gas engines and gas turbines, and for gasoline recovery.
  • the high selectivity epoxysilicone-cross-linked polyimide membrane described in the present invention also has immediate application to concentrate olefin in a paraffin/olefin stream for olefin cracking application.
  • the high selectivity epoxysilicone-cross- linked polyimide membrane can be used for propylene/propane separation to increase the concentration of the effluent in a catalytic dehydrogenation reaction for the production of propylene from propane and isobutylene from isobutane. Therefore, the number of stages of a propylene/propane splitter that is required to get polymer grade propylene can be reduced.
  • Another application for the high selectivity epoxysilicone-cross-linked polyimide membrane is for separating isoparaffin and normal paraffin in light paraffin isomerization and
  • MaxEneTM a process for enhancing the concentration of normal paraffin (n-paraffin) in the naphtha cracker feedstock, which can be then converted to ethylene.
  • the high selectivity epoxysilicone-cross-linked polyimide membrane can also be operated at high temperature to provide the sufficient dew point margin for natural gas upgrading (e.g, C0 2 removal from natural gas).
  • the high selectivity epoxysilicone-cross- linked polyimide membrane described in the present invention can be used in either a single stage membrane or as the first or/and second stage membrane in a two stage membrane system for natural gas upgrading.
  • the PI-A-ESi/P84-PES epoxysilicone-cross-linked polyimide thin film composite (TFC) hollow fiber membrane comprising an epoxysilicone-cross-linked poly(2,2'-bis-(3,4- dicarboxyphenyl)hexafluoropropane dianhydride-3,3'-dihydroxy-4,4'-diamino-biphenyl-3,3'- diacetoxy-4,4'-diamino-biphenyl) (abbreviated as PI-A) polyimide is fabricated via a co- extrusion phase inversion spinning process from a sheath dope and a core dope using a triple- orifice spinneret.
  • TFC thin film composite
  • the core dope comprises polyethersulfone (PES) polymer, P84 polyimide, NMP, L1NO 3 and lactic acid was prepared.
  • the sheath dope comprises PI-A, NMP, 1,3- dioxolane, isopropanol, and acetone was also prepared.
  • the core dope and sheath dope were co-extruded through a triple-orifice spinneret at 50 C.
  • a bore fluid containing 20% by weight of water in NMP was injected to the bore of the fiber simultaneously with the co-extruding of the core dope and sheath dope.
  • the ratio of the core dope flow rate, the sheath dope flow rate, and the bore fluid flow rate was 10: 1 : 2.7.
  • the nascent fiber traveled through an air gap length of 13 cm at room temperature, and then was immersed into a water coagulant bath at 0°C and wound up at a rate of 23 m/min.
  • the water-wet fiber was annealed in a hot water bath at 85°C for 30 minutes.
  • the annealed water-wet fiber was then sequentially exchanged with methanol and hexane for three times and for 30 minutes each time, followed by drying at 85°C in an oven for 1 hour to form dried TFC hollow fiber membrane.
  • the PI-A polyimide on the sheath layer was further cross-linked with an UV curable epoxysilicone SilForce* UV9315 purchased from Momentive in the presence of a bis(dodecylphenyl)iodonium salt photocatalyst SilForce* UV9380C purchased from Momentive under UV radiation for 3 min to form the high selectivity epoxysilicone-cross-linked polyimide thin film composite hollow fiber membrane PI-A-ESi/P84-PES.
  • an UV curable epoxysilicone SilForce* UV9315 purchased from Momentive in the presence of a bis(dodecylphenyl)iodonium salt photocatalyst SilForce* UV9380C purchased from Momentive under UV radiation for 3 min to form the high selectivity epoxysilicone-cross-linked polyimide thin film composite hollow fiber membrane PI-A-ESi/P84-PES.
  • the PI-A/P84-PES polyimide TFC hollow fiber membrane comprising un-cross- linked PI-A polyimide is fabricated via a co-extrusion phase inversion spinning process from a sheath dope and a core dope using a triple-orifice spinneret.
  • the core dope comprises PES polymer, P84 polyimide, MP, L1NO 3 and lactic acid was prepared.
  • the sheath dope comprises PI-A, NMP, 1,3-dioxolane, isopropanol, and acetone was also prepared.
  • the core dope and sheath dope were co-extruded through a triple-orifice spinneret at 50°C.
  • a bore fluid containing 20% by weight of water in NMP was injected to the bore of the fiber simultaneously with the co-extruding of the core dope and sheath dope.
  • the ratio of the core dope flow rate, the sheath dope flow rate, and the bore fluid flow rate was 10: 1 : 2.7.
  • the nascent fiber traveled through an air gap length of 13 cm at room temperature, and then was immersed into a water coagulant bath at 0°C and wound up at a rate of 23 m/min.
  • the water- wet fiber was annealed in a hot water bath at 85°C for 30 minutes.
  • the annealed water-wet fiber was then sequentially exchanged with methanol and hexane for three times and for 30 minutes each time, followed by drying at 85°C in an oven for 1 hour to form dried TFC hollow fiber membrane.
  • the membrane was further coated with a thin layer of thermally curable RTV silicone rubber and cured at 85°C in an oven for 1 hour to form the final PI- A/P84-PES TFC hollow fiber membrane.
  • the PI-A-ESi/P84-PES epoxysilicone-cross-linked polyimide TFC hollow fiber membrane showed high C0 2 /CH 4 separation performance with CO 2 permeance of 69 GPU and CO 2 /CH 4 selectivity of 30.6 for CO 2 /CH 4 separation at 50°C under 5617 kPa feed pressure with 10% C0 2 and 90% CH 4 in the feed gas.
  • the PI-A/P84-PES un-cross-linked polyimide TFC hollow fiber membrane showed higher CO 2 permeance (123 GPU) and significantly lower CO 2 /CH 4 selectivity (11.8) than the PI-A-ESi/P84-PES epoxysilicone-cross-linked polyimide TFC hollow fiber membrane even though the PI-A/P84-PES un-cross-linked polyimide TFC hollow fiber membrane has been coated with a thin layer of thermally cured RTV silicone.
  • the PI-B-ESi/P84-PES epoxysilicone-cross-linked polyimide TFC hollow fiber membrane comprising an epoxysilicone-cross-linked poly(2,2'-bis-(3,4- dicarboxyphenyl)hexafluoropropane dianhydride-3,3'-dihydroxy-4,4'-diamino-biphenyl-3,3'- diacetoxy-4,4'-diamino-biphenyl-3,5-diaminobenzoic acid) (abbreviated as PI-B) is fabricated via a co-extrusion phase inversion spinning process from a sheath dope and a core dope using a triple-orifice spinneret using a procedure similar to that for PI-A-ESi/P84-PES TFC hollow fiber membrane as described in Example 1, but PI-B polymer instead of PI-A is used for the sheath layer.
  • the PI-B/P84-PES TFC hollow fiber membrane comprising un-cross-linked PI-A polyimide is fabricated via a co-extrusion phase inversion spinning process from a sheath dope and a core dope using a triple-orifice spinneret using a procedure similar to that for PI- A/P84-PES TFC hollow fiber membrane as described in Comparable Example 1, but PI-B polymer instead of PI-A is used for the sheath layer.
  • the PI-B-ESi/P84-PES epoxysilicone-cross-linked polyimide TFC hollow fiber membrane showed high C0 2 /CH 4 separation performance with CO 2 permeance of 51 GPU and CO 2 /CH 4 selectivity of 26.2 for CO 2 /CH 4 separation at 50°C under 5617 kPa feed pressure with 10% C0 2 and 90% CH 4 in the feed gas.
  • the PI-B/P84-PES un-cross-linked polyimide TFC hollow fiber membrane showed higher CO 2 permeance (69 GPU) and significantly lower CO 2 /CH 4 selectivity (12.2) than the PI-B-ESi/P84-PES epoxysilicone-cross-linked polyimide TFC hollow fiber membrane even though the PI-B/P84-PES un-cross-linked polyimide TFC hollow fiber membrane has been coated with a thin layer of thermally cured RTV silicone.
  • a first embodiment of the invention is a epoxysilicone-cross-linked polyimide membrane comprising an epoxysilicone-cross-linked polyimide polymer wherein the polyimide polymer comprises hydroxyl functional groups cross-linked with epoxy functional groups on the epoxysilicone polymer wherein the epoxysilicone-cross-linked polyimide olymer comprises a plurality of repeating units of formula (I), wherein formula (I) is
  • R is selected from the group consisting of
  • R is selected from the group consisting of hydrogen, methyl, and ethyl, and wherein j, k, 1, m, n, p, x, y, z, and u are positive integers and j, k, 1, n, p, u, and z may be zero;
  • XI and X2 are selected from the group consisting of
  • XI and X2 are the same or different from each other; wherein Yl is selected from the group consisting of
  • R" is selected from the group consisting of
  • R' " is selected from the group consisting of -H, COCH3, and mixtures thereof
  • Y2 is selected from the group consisting of
  • R" is selected from the group consisting of
  • R" ' is selected from the group consisting of -H, COCH3, and mixtures thereof; and wherein a, b, and c are independent integers from 1 to 500.
  • An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the first embodiment in this paragraph wherein in formula (I), XI and X2 are selected from the group consisting of
  • An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the first embodiment in this paragraph wherein in formula (I), Yl is selected from the group consisting of
  • R" ' is selected from the group consisting of -H, COCH3, and mixtures thereof.
  • An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the first embodiment in this paragraph wherein in formula (I), Y2 wherein R' " is selected from the group consisting of -H, COCH3, and mixtures thereof.
  • Yl is selected from the group consisting of
  • R' " is selected from the group consisting of -H, COCH3, and mixtures thereof.
  • An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the first embodiment in this paragraph is in a form selected from an asymmetric integrally skinned membrane, a thin film composite (TFC) membrane or a hollow fiber membrane.
  • An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the first embodiment in this paragraph wherein the thin film composite comprises a thin nonporous selective separation layer comprising an epoxysilicone-cross-linked polyimide polymer and a porous nonselective mechanical support layer made from a material different from the epoxysilicone-cross-linked polyimide polymer.
  • an embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the first embodiment in this paragraph wherein the porous nonselective mechanical support layer comprises a polymer selected from the group consisting of polysulfones, sulfonated polysulfones, polyethersulfones, sulfonated polyethersulfones, polyethers, polyetherimides, cellulosic polymers such as cellulose acetate and cellulose triacetate, polyamides, polyimides, polyether ketones, and mixtures thereof
  • the polyimide polymer with hydroxyl functional groups comprises poly(2,2'-bis-(3,4-dicarboxyphenyl)hexafluoropropane dianhydride-3,3'- dihydroxy-4,4'-diamino-biphenyl-3,3'-diacetoxy-4,4'-dia
  • R is selected from the group consisting of
  • R is selected from the group consisting of hydrogen, methyl, and ethyl, and wherein j, k, 1, m, n, p, x, y, z, and u are positive integers and j, k, 1, n, p, u, and z may be zero;
  • XI and X2 are selected from the group consisting of
  • XI and X2 are the same or different from each other; wherein Yl is selected from the group consisting of
  • R" is selected from the group consisting of
  • R" ' is selected from the group consisting of -H, COCH3, and mixtures thereof
  • Y2 is selected from the group consisting of
  • R" is selected from the group consisting of
  • R" ' is selected from the group consisting of -H, COCH3, and mixtures thereof; and wherein a, b, and c are independent integers from 1 to 500, the process comprising (a) providing the epoxysilicone-cross-linked polyimide membrane described in the present invention which is permeable to the at least one gas; (b) contacting the mixture on one side of the epoxysilicone-cross-linked polyimide membrane to cause the at least one gas to permeate the membrane; and (c) removing from the opposite side of the membrane a permeate gas composition comprising a portion of the at least one gas which permeated the membrane.
  • An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the second embodiment in this paragraph wherein in formula (I), XI and X2 are selected from the group consisting of
  • An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the second embodiment in this paragraph wherein in formula (I), Yl is selected from th roup consisting of
  • R" ' is selected from the group consisting of -H, COCH3, and mixtures thereof.
  • An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the second embodiment in this paragraph wherein in formula (I), Y2 is
  • R' " is selected from the group consisting of -H, COCH3, and mixtures thereof.
  • An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the second embodiment in this paragraph wherein in formula (I), R is selected from the group consisting of MDxDEyM, MEDxDEyME, MEDxDEyM, and mixtures thereof; wherein
  • Yl is selected from the group consisting of
  • R" ' is selected from the group consisting of -H, COCH3, and mixtures thereof.
  • An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the second embodiment in this paragraph wherein the mixture of gases is selected from the group consisting of volatile organic compounds in nitrogen or oxygen; carbon dioxide or hydrogen sulfide in natural gas; hydrogen, nitrogen, methane and argon; hydrogen in a mixture with hydrocarbons; olefins and paraffins; iso and normal paraffins; nitrogen and oxygen; carbon dioxide and methane; hydrogen and methane; carbon monoxide, helium and methane; and carbon dioxide, oxygen, nitrogen, water vapor, hydrogen sulfide, helium and other trace gases in raw natural gas.
  • An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the second embodiment in this paragraph wherein the mixture of gases is separated at a temperature from -20° to 100°C and a pressure from 275 kPa to 2.6 MPa.
  • An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the second embodiment in this paragraph wherein the mixture comprises hydrogen and methane.
  • An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the second embodiment in this paragraph wherein the mixture comprises carbon dioxide in natural gas.

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Abstract

The present invention provides a high selectivity epoxysilicone-cross-linked polyimide membrane comprising a polyimide polymer with hydroxyl functional groups cross-linked with epoxy functional groups on epoxysilicone polymer. The present invention also provides a process for separating at least one gas from a mixture of gases using the high selectivity epoxysilicone-cross-linked polyimide membrane. The process comprises providing the high selectivity epoxysilicone-cross-linked polyimide membrane which is permeable to the at least one gas; contacting the mixture on one side of the membrane to cause the at least one gas to permeate the membrane; and removing from the opposite side of the membrane a permeate gas composition comprising a portion of the at least one gas which permeated the high selectivity epoxysilicone-cross-linked polyimide membrane.

Description

HIGH SELECTIVITY EPOXYSILICO E-CROSS-LINKED POLYIMIDE MEMBRANES FOR GAS SEPARATIONS
STATEMENT OF PRIORITY
[0001] This application claims priority to U.S. Application No. 14/661591 which was filed March 18, 2015, the contents of which are hereby incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] This invention relates to a high selectivity epoxysilicone-cross-linked polyimide membrane comprising a polyimide polymer with hydroxyl functional groups cross-linked with epoxy functional groups on epoxysilicone polymer under UV radiation and methods for making and using the membrane.
[0003] In the past 30-35 years, the state of the art of polymer membrane-based gas separation processes has evolved rapidly. Membrane-based technologies have advantages of both low capital cost and high-energy efficiency compared to conventional separation methods. Membrane gas separation is of special interest to petroleum producers and refiners, chemical companies, and industrial gas suppliers. Several applications of membrane gas separation have achieved commercial success, including N2 enrichment from air, carbon dioxide removal from natural gas and from enhanced oil recovery, and also in hydrogen removal from nitrogen, methane, and argon in ammonia purge gas streams. For example, UOP's Separex™ cellulose acetate spiral wound polymeric membrane is currently an international market leader for carbon dioxide removal from natural gas.
[0004] Polymers provide a range of properties including low cost, permeability, mechanical stability, and ease of processability that are important for gas separation. Glassy polymers (i.e., polymers at temperatures below their Tg) have stiffer polymer backbones and therefore let smaller molecules such as hydrogen and helium pass through more quickly, while larger molecules such as hydrocarbons pass through more slowly as compared to polymers with less stiff backbones. Cellulose acetate (CA) glassy polymer membranes are used extensively in gas separation. Currently, such CA membranes are used for natural gas upgrading, including the removal of carbon dioxide. Although CA membranes have many advantages, they are limited in a number of properties including selectivity, permeability, and in chemical, thermal, and mechanical stability.
[0005] The membranes most commonly used in commercial gas and liquid separation applications are asymmetric polymeric membranes and have a thin nonporous selective skin layer that performs the separation. Separation is based on a solution-diffusion mechanism. This mechanism involves molecular-scale interactions of the permeating gas with the membrane polymer. The mechanism assumes that in a membrane having two opposing surfaces, each component is sorbed by the membrane at one surface, transported by a gas concentration gradient, and desorbed at the opposing surface. According to this solution- diffusion model, the membrane performance in separating a given pair of gases (e.g.,
CO2/CH4, O2/N2, H2/CH4) is determined by two parameters: the permeability coefficient
(abbreviated hereinafter as permeability or PA) and the selectivity (OCA/B)- The PA is the product of the gas flux and the selective skin layer thickness of the membrane, divided by the pressure difference across the membrane. The ocA/B is the ratio of the permeability coefficients of the two gases (ocA/B = PA/PB) where PA is the permeability of the more permeable gas and PB is the permeability of the less permeable gas. Gases can have high permeability coefficients because of a high solubility coefficient, a high diffusion coefficient, or because both coefficients are high. In general, the diffusion coefficient decreases while the solubility coefficient increases with an increase in the molecular size of the gas. In high performance polymer membranes, both high permeability and selectivity are desirable because higher permeability decreases the size of the membrane area required to treat a given volume of gas, thereby decreasing capital cost of membrane units, and because higher selectivity results in a higher purity product gas.
[0006] One of the components to be separated by a membrane must have a sufficiently high permeance at the preferred conditions or an extraordinarily large membrane surface area is required to allow separation of large amounts of gases or liquids. Permeance, measured in Gas Permeation Units (GPU, 1 GPU=10-6 cm3 (STP)/cm2 s (cm Hg)), is the pressure normalized flux and is equal to permeability divided by the skin layer thickness of the membrane. Commercially available gas separation polymer membranes, such as CA, polyimide, and polysulfone membranes formed by phase inversion and solvent exchange methods have an asymmetric integrally skinned membrane structure. Such membranes are characterized by a thin, dense, selectively semipermeable surface "skin" and a less dense void-containing (or porous), non-selective support region, with pore sizes ranging from large in the support region to very small proximate to the "skin". However, fabrication of defect- free high selectivity asymmetric integrally skinned polyimide membranes is difficult. The presence of nanopores or defects in the skin layer reduces the membrane selectivity. The high shrinkage of the polyimide membrane on cloth substrate during membrane casting and drying process results in unsuccessful fabrication of asymmetric integrally skinned polyimide flat sheet membranes using phase inversion technique.
[0007] US 2005/0268783 Al disclosed chemically cross-linked polyimide hollow fiber membranes prepared from a monoesterified polymer followed by final cross-linking after hollow fiber formation.
[0008] US 7,485,173 disclosed UV cross-linked mixed matrix membranes via UV radiation. The cross-linked mixed matrix membranes comprise microporous materials dispersed in the continuous UV cross-linked polymer matrix.
[0009] US 8,016, 124 disclosed a thin film composite membrane (TFC) comprising a blend of polyethersulfone and aromatic polyimide polymers. The TFC membrane has a layer of a blend of polyethersulfone and aromatic polyimide with a thickness from 0.1 to 3 microns.
[0010] US 8,337,598 disclosed a TFC hollow fiber membrane with a core player and a sheath UV-crosslinked polyimide polymer layer.
[0011] Integrally-skinned asymmetric membranes have a selective thin layer and a porous layer from the same membrane material and formed from the same membrane solution at the same time.
[0012] The present invention discloses a high selectivity epoxysilicone-cross-linked polyimide membrane comprising a polyimide polymer with hydroxyl functional groups cross-linked with epoxy functional groups on epoxysilicone polymer under UV radiation, methods for making the membrane, and the use of the membrane for natural gas upgrading and H2 purification.
SUMMARY OF THE INVENTION
[0013] This invention pertains to a high selectivity epoxysilicone-cross-linked polyimide membrane comprising a polyimide polymer with hydroxyl functional groups cross-linked with epoxy functional groups on epoxysilicone polymer under UV radiation, methods for making the membrane, and the use of the membrane for natural gas upgrading and H2 purification. This invention pertains to a thin film composite membrane or an asymmetric integrally skinned membrane comprising a high selectivity epoxysilicone-cross-linked polyimide selective skin layer with hydroxyl functional groups on the polyimide polymer chain cross-linked with epoxy functional groups on epoxysilicone polymer chain under UV radiation. The high selectivity epoxysilicone-cross-linked polyimide membrane can have either flat sheet or hollow fiber geometry.
[0014] The present invention provides a high selectivity epoxysilicone-cross-linked polyimide membrane. The cross-linking between the polyimide polymer comprising hydroxyl functional groups and the epoxysilicone polymer comprising epoxy functional groups in the present invention provides the epoxysilicone-cross-linked polyimide membrane not only high selectivity, but also high plasticization and chemical resistance due to the formation of cross- linked polymer chain segments through possible direct covalent bonds.
[0015] The present invention provides a high selectivity epoxysilicone-cross-linked polyimide membrane comprising an epoxysilicone-cross-linked polyimide wherein the polyimide polymer with hydroxyl functional groups cross-linked with epoxy functional groups on epoxysilicone polymer. The epoxysilicone-cross-linked polyimide polymer comprises a plurality of repeating units of formula (I), wherein formula (I) is
Figure imgf000005_0001
wherein R is selected from the group consisting of
MDxDE yQzTuDRfjDAkDPi(D (CH(R')CH20)m)nDBpM,
MEDxDEyQzTuDRfjDAkDPl(D'(CH(R )CH20)m)nDBpME, MEDxDEyQzTuDRfjDAkDPl(D'(CH(R )CH20)m)nDBpM,
and mixtures thereof; wherein
M= (CH3) 3SiOi/2,
ME=
Figure imgf000006_0001
D= (CH3)2Si02/2,
D' = (CH3) 3Si02/2,
DE =
Figure imgf000006_0002
O = (CF3CH2CH2)(CH3) Si02/2,
DA= ((HO)(C2H3)C6H9(CH2)2(CH3)Si02/2,
Dp= ((HO)(C6H4)(CH2)3)(CH3)Si02/2,
DB= ((C6H5COO)(HO)(C6H9)(CH2)2)(CH3)Si02/2,
Q= Si04/2,
T= (CH3)3Si03/2,
wherein R is selected from the group consisting of hydrogen, methyl, and ethyl, and wherein j, k, 1, m, n, p, x, y, z, and u are positive integers andj, k, 1, n, p, u, and z may be zero;
wherein Xi and X2 are selected from the group consisting of
Figure imgf000006_0003
and mixtures thereof, respectively; Xi and X2 are the same or different from each other; wherein Y1 is selected from the group consisting of
Figure imgf000007_0001
and mixtures thereof, R' ' is selected from the group consisting of
Figure imgf000007_0002
and mixtures thereof, and R" ' is selected from the group consisting of -H, COCH3, and mixtures thereof; Y2 is selected from the group consisting of
Figure imgf000007_0003
and mixtures thereof, R" is selected from the group consisting of
CF3 CH3 O
— ? C—F3 — ί CH—3 — O I— — 0— — s— and mixtures thereof, and R" ' is selected from the group consisting of -H, COCH3, and mixtures thereof; wherein a, b, and c are independent integers from 1 to 500. Within formula (I), preferably Xi and X2 are selected from the group consisting of
Figure imgf000008_0001
and mixtures thereof, respectively; Xi and X2 are the same or different from each other; preferably Yi is selected from the group consisting of
Figure imgf000008_0002
and mixtures thereof, wherein R" ' is selected from the group consisting of -H, COCH3, and mixtures thereof; preferably Y2 is
Figure imgf000008_0003
preferably R is selected from the group consisting of MDxDEyM, MEDxDEyME
MEDxDEyM, and mixtures thereof; wherein
Figure imgf000008_0004
D= (CH3)2Si02/2, DE =
Figure imgf000009_0001
wherein x and y are positive integers. Within formula (I), more preferably X1 is
Figure imgf000009_0002
more preferably X2 is
Figure imgf000009_0003
and mixtures thereof, wherein R" ' is selected from the group consisting of -H, COCH3, and mixtures thereof.
[0016] The high selectivity epoxysilicone-cross-linked polyimide membrane in the present invention can be either asymmetric integrally skinned membrane or thin film composite (TFC) membrane.
[0017] The asymmetric integrally-skinned flat sheet or hollow fiber high selectivity epoxysilicone-cross-linked polyimide membrane in the present invention was prepared by a phase inversion process.
[0018] The membrane dope formulation for the preparation of the asymmetric integrally- skinned flat sheet or hollow fiber high selectivity epoxysilicone-cross-linked polyimide membrane in the present invention comprises good solvents for the polyimide polymer with hydroxyl functional groups in the present invention that can completely dissolve the polymer. Representative good solvents for use in this invention include N-methylpyrrolidone (NMP), Ν,Ν-dimethyl acetamide (DMAC), methylene chloride, Ν,Ν-dimethylformamide (DMF), dimethyl sulfoxide (DMSO), dioxanes, 1,3-dioxolane, acetone, mixtures thereof, others known to those skilled in the art and mixtures thereof. In some cases, the membrane dope formulation for the preparation of asymmetric integrally-skinned flat sheet or hollow fiber high selectivity epoxysilicone-cross-linked polyimide membrane in the present invention also comprises poor solvents that cannot dissolve the polyimide polymer with hydroxyl functional groups such as methanol, ethanol, tetrahydrofuran (THF), toluene, n-octane, n-decane, lactic acid, citric acid, and mixtures thereof. It is believed that the proper weight ratio of the solvents used in the present invention provides asymmetric integrally-skinned flat sheet or hollow fiber high selectivity epoxysilicone-cross-linked polyimide membrane with less than 200 nm super thin nonporous selective skin layer which results in high permeances.
[0019] The thin film composite high selectivity epoxysilicone-cross-linked polyimide membrane described in the current invention comprises a thin nonporous selective separation layer comprising epoxysilicone-cross-linked polyimide described in the present invention and a porous nonselective mechanical support layer made from a material different from the epoxysilicone-cross-linked polyimide described in the present invention. The porous nonselective mechanical support layer made from a material different from the polyimide polymer with hydroxyl functional groups described in the present invention with a low selectivity and high flux can be made from materials including cellulose acetate, cellulose triacetate, polysulfone, polyethersulfone, polyamide, polyimide, polyetherimide,
polyurethane, polycarbonate, polystyrene, polybenzoxazole, or mixtures thereof.
[0020] One epoxysilicone-cross-linked polyimide thin film composite hollow fiber membrane comprising an epoxysilicone-cross-linked polyimide described in the present invention is fabricated via a co-extrusion phase inversion spinning process from a sheath dope and a core dope using a triple-orifice spinneret. The core dope comprises an
inexpensive, commercially available polyethersulfone (PES) polymer and an inexpensive commercially available P84 polyimide. The sheath dope comprises a poly(2,2'-bis-(3,4- dicarboxyphenyl)hexafluoropropane dianhydride-3,3'-dihydroxy-4,4'-diamino-biphenyl-3,3'- diacetoxy-4,4'-diamino-biphenyl) (abbreviated as PI-A). The PI-A polyimide was
synthesized from a condensation reaction of 2,2'-bis-(3,4- dicarboxyphenyl)hexafluoropropane dianhydride (6FDA) with 3,3'-dihydroxy-4,4'-diamino- biphenyl (HAB) in DMAc or MP polar solvent by a two-step process involving the formation of the poly(amic acid) followed by a solution imidization process. Acetic anhydride was used as the dehydrating agent and pyridine was used as the imidization catalyst for the solution imidization reaction during the second step synthesis. The core dope and sheath dope were co-extruded through a triple-orifice spinneret at a certain spinning temperature. A bore fluid containing 20% by weight of water in MP was injected to the bore of the fiber simultaneously with the co-extruding of the core dope and sheath dope. The ratio of the core dope flow rate and the sheath dope flow rate was controlled to be in a range of 3 : 1 to 10: 1. The dried thin film composite hollow fiber membrane was further cross-linked with an UV curable epoxysilicone SilForce* UV9315 purchased from Momentive,
Columbus, Ohio, in the presence of a bis(dodecylphenyl)iodonium salt photocatalyst SilForce UV9380C ("SilForce" is a trademark of Momentive Performance Materials, Inc.) purchased from Momentive to form the high selectivity epoxysilicone-cross-linked polyimide thin film composite hollow fiber membrane PI-A-ESi/P84-PES.
[0021] The PI-A-ESi/P84-PES epoxysilicone-cross-linked polyimide thin film composite hollow fiber membrane showed high CO2/CH4 separation performance with CO2 permeance of 69 GPU and CO2/CH4 selectivity of 30.6 for CO2/CH4 separation at 50°C under 5617 kPa feed pressure with 10% CO2 and 90% CH4 in the feed gas.
[0022] The invention provides a process for separating at least one gas from a mixture of gases using the high selectivity epoxysilicone-cross-linked polyimide membrane comprising an epoxysilicone-cross-linked polyimide described herein, the process comprising: (a) providing a high selectivity epoxysilicone-cross-linked polyimide membrane described in the present invention which is permeable to said at least one gas; (b) contacting the mixture on one side of the high selectivity epoxysilicone-cross-linked polyimide membrane to cause said at least one gas to permeate the membrane; and (c) removing from the opposite side of the membrane a permeate gas composition comprising a portion of said at least one gas which permeated said membrane.
[0023] The high selectivity epoxysilicone-cross-linked polyimide membranes described in the current invention are not only suitable for CO2/CH4 separation, but also suitable for a variety of other gas separations such as H2 purification, O2 2 and H2S/CH4 separations. DETAILED DESCRIPTION OF THE INVENTION
[0024] Commercially available gas separation membranes, such as CA, polyimide, and polysulfone membranes formed by phase inversion and solvent exchange methods and with either hollow fiber or flat sheet geometry have an asymmetric integrally skinned membrane structure. Such membranes are characterized by a thin, dense, selectively semipermeable surface skin layer and a less dense void-containing (or porous), non-selective support layer, with pore sizes ranging from large in the support region to very small proximate to the skin. The skin layer and the porous non-selective support layer are formed from the same membrane material and formed from the same membrane solution at the same time.
[0025] Another type of asymmetric gas separation membrane is thin-film composite (TFC) membrane. TFC membranes are also characterized by a thin, selectively
semipermeable surface skin layer and a porous non-selective support layer. However, the selective thin layer and the non-selective porous layer can be made from different materials. In addition, the selective thin layer and the non-selective porous layer can be formed from two separate steps or from a co-extrusion process of two different membrane solutions.
[0026] For the TFC flat sheet membrane formed from dip-coating or laminating process, the selective thin dense layer on the non-selective porous layer can be delaminated easily from the non-selective porous layer, which will result in significantly decreased selectivity for gas separations. On the other hand, for the TFC hollow fiber membrane formed from a co- extrusion phase inversion process, the sheath layer with a selective thin dense layer and relatively porous thin sublayer and the core non-selective porous layer are formed from a one-step phase inversion process. Therefore, the sheath layer cannot be delaminated easily from the non-selective core layer. In addition, the core non-selective porous layer of the TFC hollow fiber membrane can be made from low cost membrane materials and the thin selective sheath layer can be made from high cost high performance new membrane material.
[0027] The use of membranes for separation of both gases and liquids is a growing technological area with potentially high economic reward due to the low energy requirements and the potential for scaling up of modular membrane designs. Advances in membrane technology, with the continuing development of new membrane materials and new methods for the production of high performance membranes will make this technology even more competitive with traditional, high-energy intensive and costly processes such as distillation.
Among the applications for large scale gas separation membrane systems are nitrogen enrichment, oxygen enrichment, hydrogen recovery, removal of hydrogen sulfide and carbon dioxide from natural gas and dehydration of air and natural gas. Also, various hydrocarbon separations are potential applications for the appropriate membrane system. The membranes that are used in these applications must have high selectivity, durability, and productivity in processing large volumes of gas or liquid in order to be economically successful. Membranes for gas separations have evolved rapidly in the past 25 years due to their easy processability for scale-up and low energy requirements. More than 90% of the membrane gas separation applications involve the separation of noncondensable gases: such as nitrogen from air, and hydrogen from nitrogen, argon or methane. Membrane gas separation is of special interest to petroleum producers and refiners, chemical companies, and industrial gas suppliers. Several applications of membrane gas separation have achieved commercial success, including nitrogen enrichment from air, hydrogen from nitrogen, argon or methane, carbon dioxide removal from natural gas and biogas and in enhanced oil recovery.
[0028] The present invention provides a high selectivity epoxysilicone-cross-linked polyimide membrane comprising a polyimide polymer with hydroxyl functional groups cross-linked with epoxy functional groups on epoxysilicone polymer in the presence of an effective amount of a bis(dodecylphenyl)iodonium salt photocatalyst under UV radiation. This invention also pertains to the application of the high selectivity epoxysilicone-cross- linked polyimide membrane for ¾ purifications such as H2/CH4 separation, and also for a variety of other gas separations such as separations of CO2/CH4, H2S/CH4, CO2/N2, olefin/paraffin (e.g. propylene/propane), and O2/N2 separations.
[0029] This invention pertains to a thin film composite membrane or an asymmetric integrally skinned membrane comprising a high selectivity epoxysilicone-cross-linked polyimide selective skin layer with hydroxyl functional groups on the polyimide polymer chain cross-linked with epoxy functional groups on epoxysilicone polymer chain in the presence of the bis(dodecylphenyl)iodonium salt photocatalyst under UV radiation. The high selectivity epoxysilicone-cross-linked polyimide membrane can have either flat sheet or hollow fiber geometry.
[0030] The present invention provides a high selectivity epoxysilicone-cross-linked polyimide membrane. The cross-linking between the polyimide polymer comprising hydroxyl functional groups and the epoxysilicone polymer comprising epoxy functional groups in the present invention provides the epoxysilicone-cross-linked polyimide membrane not only high selectivity, but also high plasticization and chemical resistance due to the formation of cross- linked polymer chain segments through possible direct covalent bonds.
[0031] The present invention provides a high selectivity epoxysilicone-cross-linked polyimide membrane comprising an epoxysilicone-cross-linked polyimide wherein the polyimide polymer with hydroxyl functional groups cross-linked with epoxy functional groups on epoxysilicone polymer. The epoxysilicone-cross-linked polyimide polymer comprises a plurality of repeating units of formula (I), wherein formula (I) is
Figure imgf000014_0001
wherein R is selected from the group consisting of
MDxDE yQzTuDRf JDA kDp 1(D'(CH(R )CH20)m)nDB pM,
MEDxDE yQzTuDRf JDA kDp 1(D'(CH(R )CH20)m)nDB pME,
MEDxDE yQzTuDRf JDA kDp 1(D (CH(R )CH20)m)nDB pM,
and mixtures thereof; wherein
Figure imgf000014_0002
Figure imgf000014_0003
(CH3)2Si02/2,
= (CH3) 3Si02/2,
Figure imgf000015_0001
ϋω= (CF3CH2CH2)(CH3) Si02/2,
DA= ((HO)(C2H3)C6H9(CH2)2(CH3)Si02/2,
Dp= ((HO)(C6H4)(CH2)3)(CH3)Si02/2,
DB= ((C6H5COO)(HO)(C6H9)(CH2)2)(CH3)Si02/2,
Q= Si04/2,
T= (CH3)3Si03/2,
wherein R is selected from the group consisting of hydrogen, methyl, and ethyl, and wherein j, k, 1, m, n, p, x, y, z, and u are positive integers andj, k, 1, n, p, u, and z may be zero;
wherein X1 and X2 are selected from the group consisting of
Figure imgf000015_0002
and mixtures thereof, respectively; X1 and X2 are the same or different from each other; wherein Yi is selected from the group consisting of
Figure imgf000015_0003
and mixtures thereof, R" is selected from the group consisting of
Figure imgf000016_0001
and mixtures thereof, and R'" is selected from the group consisting of -H, COCH3, and mixtures thereof; Y2 is selected from the roup consisting of
Figure imgf000016_0002
and mixtures thereof, R" is selected from the group consisting of
Figure imgf000016_0003
and mixtures thereof, and R" ' is selected from the group consisting of -H, COCH3, and mixtures thereof; wherein a, b, and c are independent integers from 1 to 500. Within formula (I), preferably Xi and X2 are selected from the group consisting of
Figure imgf000016_0004
and mixtures thereof, respectively; Xi and X2 are the same or different from each other; preferably Yi is selected from the group consisting of
Figure imgf000017_0001
and mixtures thereof, wherein R" ' is selected from the group consisting of -H, COCH3, and mixtures thereof; preferably Y2 is
Figure imgf000017_0002
preferably R is selected from the group consisting of MDxDEyM, MEDxDEyME
MEDxDEyM, and mixtures thereof; wherein
M= (CH3)3SiOi/2,
ME=
Figure imgf000017_0003
D= (CH3)2Si02/2,
DE =
Figure imgf000017_0004
wherein x and are positive integers. Within formula (I), more preferably Xi is
Figure imgf000017_0005
more preferably X2 is
Figure imgf000018_0001
more preferably Y1 is selected from the group consisting of
Figure imgf000018_0002
and mixtures thereof, wherein R" ' is selected from the group consisting of -H, COCH3, and mixtures thereof.
[0032] The polyimide polymer with hydroxyl functional groups used for the preparation of the high selectivity epoxysilicone-cross-linked polyimide membrane in the present invention comprises a plurality of repeating units of formula (II), wherein formula (II) is
Figure imgf000018_0003
wherein Xi and X2 are selected from the group consisting of
Figure imgf000018_0004
and mixtures thereof, respectively; Xi and X2 are the same or different from each other; wherein Yi is selected from the group consisting of
Figure imgf000019_0001
and mixtures thereof, R" is selected from the group consisting of
Figure imgf000019_0002
and mixtures thereof, and R" ' is selected from the group consisting of -H, COCH3, and mixtures thereof; Y2-OH is selected from the group consisting of
Figure imgf000019_0003
and mixtures thereof, R" is selected from the group consisting of
Figure imgf000019_0004
and mixtures thereof, and R" ' is selected from the group consisting of -H, COCH3, and mixtures thereof; wherein a and b are independent integers from 1 to 500. Within formula (II), preferably Xi and X2 are selected from the group consisting of
Figure imgf000020_0001
and mixtures thereof, respectively; Xi and X2 are the same or different from each other; preferably Yi is selected from the group consisting of
Figure imgf000020_0002
and mixtures thereof, wherein R" ' is selected from the group consisting of -H, COCH3, and mixtures thereof; preferably Y2-OH is
Figure imgf000020_0003
Within formula (II), more preferably Xi is
Figure imgf000020_0004
more preferably X2 is
Figure imgf000020_0005
more preferably Yi is selected from the group consisting of
Figure imgf000021_0001
and mixtures thereof, wherein R" ' is selected from the group consisting of -H, COCH3, and mixtures thereof.
[0033] The polyimide polymer with hydroxyl functional groups used for making the high selectivity epoxysilicone-cross-linked membrane described in the current invention is selected from poly(2,2'-bis-(3,4-dicarboxyphenyl)hexafluoropropane dianhydride-3,3'- dihydroxy-4,4'-diamino-biphenyl-3,3'-diacetoxy-4,4'-diamino-biphenyl) (abbreviated as PI- A), poly(2,2'-bis-(3,4-dicarboxyphenyl)hexafluoropropane dianhydride-3,3'-dihydroxy-4,4'- diamino-biphenyl-3,3'-diacetoxy-4,4'-diamino-biphenyl-3,5-diaminobenzoic acid)
(abbreviated as PI-B), and a mixture thereof.
[0034] The polyimide polymer with hydroxyl functional groups used for making the high selectivity epoxysilicone-cross-linked membrane described in the current invention have a weight average molecular weight in the range of 50,000 to 1,000,000 Daltons, preferably between 70,000 to 500,000 Daltons.
[0035] The epoxysilicone polymer with epoxy functional groups used for the preparation of the high selectivity epoxysilicone-cross-linked polyimide membrane in the present invention is selected from the group consisting of
MDxDE yQzTuDRf JDA kDp 1(D'(CH(R )CH20)m)nDB pM,
MEDxDE yQzTuDRf JDA kDp 1(D (CH(R )CH20)m)nDB pME,
MEDxDE yQzTuDRf jDA kDPi(D'(CH(R )CH20)m)nDB pM, and mixtures thereof; wherein
Figure imgf000021_0002
Figure imgf000021_0003
(CH3)2Si02/2,
= (CH3) 3Si02/2, DE
Figure imgf000022_0001
Om= (CF3CH2CH2)(CH3) Si02/2,
DA= ((HO)(C2H3)C6H9(CH2)2(CH3)Si02/2,
Dp= ((HO)(C6H4)(CH2)3)(CH3)Si02/2,
DB= ((C6H5COO)(HO)(C6H9)(CH2)2)(CH3)Si02/2,
Q= Si04/2,
T= (CH3)3Si03/2,
wherein R is selected from the group consisting of hydrogen, methyl, and ethyl, and wherein j, k, 1, m, n, p, x, y, z, and u are positive integers and j, k, 1, n, p, u, and z may be zero.
Preferably the epoxysilicone polymer with epoxy functional groups used for the preparation of the high selectivity epoxysilicone-cross-linked polyimide membrane in the present invention is selected from the group consisting of MDxDE yM, MEDxDE yME, MEDxDE yM, and mixtures thereof; wherein
Figure imgf000022_0002
ME=
Figure imgf000022_0003
(CH3)2Si02/2,
Figure imgf000022_0004
wherein x and y are positive integers.
[0036] Preferably, the epoxysilicone polymer with epoxy functional groups used for the preparation of the high selectivity epoxysilicone-cross-linked polyimide membrane in the present invention is selected from commercially available UV curable epoxysilicones, for example, Momentive SilForce* UV-photocurable epoxysilicones under the denominations of SilForce* UV9315, SilForce* UV9430, and SilForce* UV9400.
[0037] The bis(dodecylphenyl)iodonium salt photocatalyst used for the preparation of the high selectivity epoxysilicone-cross-linked polyimide membrane described in the present invention is selected from the salts of the group of acids consisting of hexafluoroantimonic acid, hexafluoroarsenic acid, hexafluorophosphoric acid, tetrafluoroboric acid,
tetra(perfluorophenyl)boric acid and mixtures thereof. An example of the iodonium photo- catalyst is the commercially available one from Momentive under the denominations of SilForce* UV9380C. Preferably, the ratio of the bis(dodecylphenyl)iodonium salt
photocatalyst and the epoxysilicone polymer used for the preparation of the high selectivity epoxysilicone-cross-linked polyimide membrane in the present invention is in a range from 100: 1 to 100: 10 by weight.
[0038] The high selectivity epoxysilicone-cross-linked polyimide membrane in the present invention can be either asymmetric integrally skinned membrane or thin film composite (TFC) membrane.
[0039] The asymmetric integrally-skinned flat sheet or hollow fiber high selectivity epoxysilicone-cross-linked polyimide membrane in the present invention was prepared by a phase inversion process.
[0040] The membrane dope formulation for the preparation of the asymmetric integrally- skinned flat sheet or hollow fiber high selectivity epoxysilicone-cross-linked polyimide membrane in the present invention comprises good solvents for the polyimide polymer with hydroxyl functional groups in the present invention that can completely dissolve the polymer. Representative good solvents for use in this invention include N-methylpyrrolidone (NMP), Ν,Ν-dimethyl acetamide (DMAC), methylene chloride, Ν,Ν-dimethylformamide (DMF), dimethyl sulfoxide (DMSO), dioxanes, 1,3-dioxolane, acetone, mixtures thereof, others known to those skilled in the art and mixtures thereof. In some cases, the membrane dope formulation for the preparation of asymmetric integrally-skinned flat sheet or hollow fiber high selectivity epoxysilicone-cross-linked polyimide membrane in the present invention also comprises poor solvents that cannot dissolve the polyimide polymer with hydroxyl functional groups such as methanol, ethanol, tetrahydrofuran (TFIF), toluene, n-octane, n-decane, lactic acid, citric acid, and mixtures thereof. It is believed that the proper weight ratio of the solvents used in the present invention provides asymmetric integrally-skinned flat sheet or hollow fiber high selectivity epoxysilicone-cross-linked polyimide membrane with less than 200 nm super thin nonporous selective skin layer which results in high permeances.
[0041] The thin film composite high selectivity epoxysilicone-cross-linked polyimide membrane comprises a thin nonporous selective separation layer comprising epoxysilicone- cross-linked polyimide described in the present invention and a porous nonselective mechanical support layer made from a material different from the epoxysilicone-cross-linked polyimide described in the present invention. The thin film composite high selectivity epoxysilicone-cross-linked polyimide membrane has either hollow fiber or flat sheet geometry.
[0042] For the preparation of TFC hollow fiber high selectivity epoxysilicone-cross- linked polyimide membrane, it is preferred that the solution of the polyimide polymer with hydroxyl functional groups has a concentration of from 20 to 40 wt%. The solution of the polyimide polymer with hydroxyl functional groups and the polymer solution for the formation of the porous nonselective mechanical support layer were co-extruded from a spinneret to form TFC hollow fiber high selectivity epoxysilicone-cross-linked polyimide membrane.
[0043] The porous nonselective mechanical support layer was made from a material different from the polyimide polymer with hydroxyl functional groups described in the present invention with a low selectivity and high flux. Selection of the porous nonselective mechanical support layer for the preparation of TFC high selectivity epoxysilicone-cross- linked polyimide membrane in the present invention may be made on the basis of the heat resistance, solvent resistance, and mechanical strength of the porous nonselective mechanical support layer, as well as other factors dictated by the operating conditions for selective permeation. The porous nonselective mechanical support layer is preferably at least partially self-supporting, and in some instances may be essentially self-supporting. The porous nonselective mechanical support layer may provide essentially all of the structural support for the membrane. Some preferred polymers different from the polyimide polymer with hydroxyl functional groups described in the present invention that are suitable for the preparation of the porous nonselective mechanical support layer for the TFC high selectivity epoxysilicone- cross-linked polyimide membrane according to the present invention include, but are not limited to, polysulfones, sulfonated polysulfones, polyethersulfones (PESs), sulfonated PESs, polyethers, polyetherimides such as Ultem, cellulosic polymers such as cellulose acetate and cellulose triacetate, polyamides, polyimides such as P84 and P84HT, polyether ketones, and mixtures thereof.
[0044] The invention provides a process for separating at least one gas from a mixture of gases using high selectivity epoxysilicone-cross-linked polyimide membrane described in the present invention, the process comprising: (a) providing a high selectivity epoxysilicone- cross-linked polyimide membrane described in the present invention which is permeable to said at least one gas; (b) contacting the mixture on one side of the high selectivity
epoxysilicone-cross-linked polyimide membrane described in the present invention to cause said at least one gas to permeate the membrane; and (c) removing from the opposite side of the membrane a permeate gas composition comprising a portion of said at least one gas which permeated said membrane.
[0045] The high selectivity epoxysilicone-cross-linked polyimide membrane described in the present invention is especially useful in the purification, separation or adsorption of a particular species in the liquid or gas phase.
[0046] The high selectivity epoxysilicone-cross-linked polyimide membrane described in the present invention is especially useful in gas separation processes in air purification, petrochemical, refinery, and natural gas industries. Examples of such separations include separation of volatile organic compounds (such as toluene, xylene, and acetone) from an atmospheric gas, such as nitrogen or oxygen and nitrogen recovery from air. Further examples of such separations are for the separation of C02 or H2S from natural gas, H2 from N2, CH4, and Ar in ammonia purge gas streams, H2 recovery in refineries, olefin/paraffin separations such as propylene/propane separation, and iso/normal paraffin separations. Any given pair or group of gases that differ in molecular size, for example nitrogen and oxygen, carbon dioxide and methane, hydrogen and methane or carbon monoxide, helium and methane, can be separated using the high selectivity epoxysilicone-cross-linked polyimide membrane described in the present invention. More than two gases can be removed from a third gas. For example, some of the gas components which can be selectively removed from a raw natural gas using the membrane described herein include carbon dioxide, oxygen, nitrogen, water vapor, hydrogen sulfide, helium, and other trace gases. Some of the gas components that can be selectively retained include hydrocarbon gases. When permeable components are acid components selected from the group consisting of carbon dioxide, hydrogen sulfide, and mixtures thereof and are removed from a hydrocarbon mixture such as natural gas, one module, or at least two in parallel service, or a series of modules may be utilized to remove the acid components. For example, when one module is utilized, the pressure of the feed gas may vary from 275 kPa to 2.6 MPa (25 to 4000 psi). The differential pressure across the membrane can be as low as 70 kPa or as high as 14.5 MPa (10 psi or as high as 2100 psi) depending on many factors such as the particular membrane used, the flow rate of the inlet stream and the availability of a compressor to compress the permeate stream if such compression is desired. Differential pressure greater than 14.5 MPa (2100 psi) may rupture the membrane. A differential pressure of at least 0.7 MPa (100 psi) is preferred since lower differential pressures may require more modules, more time and compression of intermediate product streams. The operating temperature of the process may vary depending upon the temperature of the feed stream and upon ambient temperature conditions.
Preferably, the effective operating temperature of the membranes of the present invention will range from -50° to 150°C. More preferably, the effective operating temperature of the high selectivity epoxysilicone-cross-linked polyimide membrane of the present invention will range from -20° to 100°C, and most preferably, the effective operating temperature of the membranes of the present invention will range from 25° to 100°C.
[0047] The high selectivity epoxysilicone-cross-linked polyimide membrane described in the present invention are also especially useful in gas/vapor separation processes in chemical, petrochemical, pharmaceutical and allied industries for removing organic vapors from gas streams, e.g. in off-gas treatment for recovery of volatile organic compounds to meet clean air regulations, or within process streams in production plants so that valuable compounds (e.g., vinylchloride monomer, propylene) may be recovered. Further examples of gas/vapor separation processes in which the high selectivity epoxysilicone-cross-linked polyimide membrane described in the present invention may be used are hydrocarbon vapor separation from hydrogen in oil and gas refineries, for hydrocarbon dew pointing of natural gas (i.e. to decrease the hydrocarbon dew point to below the lowest possible export pipeline temperature so that liquid hydrocarbons do not separate in the pipeline), for control of methane number in fuel gas for gas engines and gas turbines, and for gasoline recovery.
[0048] The high selectivity epoxysilicone-cross-linked polyimide membrane described in the present invention also has immediate application to concentrate olefin in a paraffin/olefin stream for olefin cracking application. For example, the high selectivity epoxysilicone-cross- linked polyimide membrane can be used for propylene/propane separation to increase the concentration of the effluent in a catalytic dehydrogenation reaction for the production of propylene from propane and isobutylene from isobutane. Therefore, the number of stages of a propylene/propane splitter that is required to get polymer grade propylene can be reduced. Another application for the high selectivity epoxysilicone-cross-linked polyimide membrane is for separating isoparaffin and normal paraffin in light paraffin isomerization and
MaxEne™, a process for enhancing the concentration of normal paraffin (n-paraffin) in the naphtha cracker feedstock, which can be then converted to ethylene.
[0049] The high selectivity epoxysilicone-cross-linked polyimide membrane can also be operated at high temperature to provide the sufficient dew point margin for natural gas upgrading (e.g, C02 removal from natural gas). The high selectivity epoxysilicone-cross- linked polyimide membrane described in the present invention can be used in either a single stage membrane or as the first or/and second stage membrane in a two stage membrane system for natural gas upgrading.
EXAMPLES [0050] The following examples are provided to illustrate one or more preferred embodiments of the invention, but are not limited embodiments thereof. Numerous variations can be made to the following examples that lie within the scope of the invention.
EXAMPLE 1
Preparation of PI-A-ESi/P84-PES epoxysilicone-cross-linked
polyimide TFC hollow fiber membrane
[0051] The PI-A-ESi/P84-PES epoxysilicone-cross-linked polyimide thin film composite (TFC) hollow fiber membrane comprising an epoxysilicone-cross-linked poly(2,2'-bis-(3,4- dicarboxyphenyl)hexafluoropropane dianhydride-3,3'-dihydroxy-4,4'-diamino-biphenyl-3,3'- diacetoxy-4,4'-diamino-biphenyl) (abbreviated as PI-A) polyimide is fabricated via a co- extrusion phase inversion spinning process from a sheath dope and a core dope using a triple- orifice spinneret. The core dope comprises polyethersulfone (PES) polymer, P84 polyimide, NMP, L1NO3 and lactic acid was prepared. The sheath dope comprises PI-A, NMP, 1,3- dioxolane, isopropanol, and acetone was also prepared. The core dope and sheath dope were co-extruded through a triple-orifice spinneret at 50 C. A bore fluid containing 20% by weight of water in NMP was injected to the bore of the fiber simultaneously with the co-extruding of the core dope and sheath dope. The ratio of the core dope flow rate, the sheath dope flow rate, and the bore fluid flow rate was 10: 1 : 2.7. The nascent fiber traveled through an air gap length of 13 cm at room temperature, and then was immersed into a water coagulant bath at 0°C and wound up at a rate of 23 m/min. The water-wet fiber was annealed in a hot water bath at 85°C for 30 minutes. The annealed water-wet fiber was then sequentially exchanged with methanol and hexane for three times and for 30 minutes each time, followed by drying at 85°C in an oven for 1 hour to form dried TFC hollow fiber membrane. The PI-A polyimide on the sheath layer was further cross-linked with an UV curable epoxysilicone SilForce* UV9315 purchased from Momentive in the presence of a bis(dodecylphenyl)iodonium salt photocatalyst SilForce* UV9380C purchased from Momentive under UV radiation for 3 min to form the high selectivity epoxysilicone-cross-linked polyimide thin film composite hollow fiber membrane PI-A-ESi/P84-PES.
COMPARATIVE EXAMPLE 1
Preparation of PI- A/P84-PES polyimide TFC hollow fiber membrane [0052] The PI-A/P84-PES polyimide TFC hollow fiber membrane comprising un-cross- linked PI-A polyimide is fabricated via a co-extrusion phase inversion spinning process from a sheath dope and a core dope using a triple-orifice spinneret. The core dope comprises PES polymer, P84 polyimide, MP, L1NO3 and lactic acid was prepared. The sheath dope comprises PI-A, NMP, 1,3-dioxolane, isopropanol, and acetone was also prepared. The core dope and sheath dope were co-extruded through a triple-orifice spinneret at 50°C. A bore fluid containing 20% by weight of water in NMP was injected to the bore of the fiber simultaneously with the co-extruding of the core dope and sheath dope. The ratio of the core dope flow rate, the sheath dope flow rate, and the bore fluid flow rate was 10: 1 : 2.7. The nascent fiber traveled through an air gap length of 13 cm at room temperature, and then was immersed into a water coagulant bath at 0°C and wound up at a rate of 23 m/min. The water- wet fiber was annealed in a hot water bath at 85°C for 30 minutes. The annealed water-wet fiber was then sequentially exchanged with methanol and hexane for three times and for 30 minutes each time, followed by drying at 85°C in an oven for 1 hour to form dried TFC hollow fiber membrane. The membrane was further coated with a thin layer of thermally curable RTV silicone rubber and cured at 85°C in an oven for 1 hour to form the final PI- A/P84-PES TFC hollow fiber membrane. EXAMPLE 3
Evaluation of CO2/CH4 separation performance of PI-A-ESi/P84-PES
and PI-A/P84-PES TFC hollow fiber membranes
[0053] The PI-A-ESi/P84-PES epoxysilicone-cross-linked polyimide TFC hollow fiber membrane and PI-A/P84-PES un-cross-linked polyimide TFC hollow fiber membrane were tested for CO2/CH4 separation at 50°C under 5617 kPa (800 psig) feed gas pressure with 10% of C02 and 90% of CH4 in the feed. The results are shown in Table 1. The PI-A-ESi/P84-PES epoxysilicone-cross-linked polyimide TFC hollow fiber membrane showed high C02/CH4 separation performance with CO2 permeance of 69 GPU and CO2/CH4 selectivity of 30.6 for CO2/CH4 separation at 50°C under 5617 kPa feed pressure with 10% C02 and 90% CH4 in the feed gas. The PI-A/P84-PES un-cross-linked polyimide TFC hollow fiber membrane showed higher CO2 permeance (123 GPU) and significantly lower CO2/CH4 selectivity (11.8) than the PI-A-ESi/P84-PES epoxysilicone-cross-linked polyimide TFC hollow fiber membrane even though the PI-A/P84-PES un-cross-linked polyimide TFC hollow fiber membrane has been coated with a thin layer of thermally cured RTV silicone.
TABLE 1
CO2/CH4 separation performance of PI-A-ESi/P84-PES epoxysilicone-cross-linked polyimide TFC hollow fiber membrane and PI-A/P84-PES un-cross-linked polyimide TFC hollow fiber membrane
Figure imgf000029_0001
1 GPU= 10"6 cm3 (STP)/cm2 s (cm Hg)
Testing conditions: 50°C, 5617 kPa (800 psig) feed gas pressure,
10% C02 and 90% of CH4 in the feed.
EXAMPLE 4
Preparation of PI-B-ESi/P84-PES epoxysilicone-cross-linked
polyimide TFC hollow fiber membrane
[0054] The PI-B-ESi/P84-PES epoxysilicone-cross-linked polyimide TFC hollow fiber membrane comprising an epoxysilicone-cross-linked poly(2,2'-bis-(3,4- dicarboxyphenyl)hexafluoropropane dianhydride-3,3'-dihydroxy-4,4'-diamino-biphenyl-3,3'- diacetoxy-4,4'-diamino-biphenyl-3,5-diaminobenzoic acid) (abbreviated as PI-B) is fabricated via a co-extrusion phase inversion spinning process from a sheath dope and a core dope using a triple-orifice spinneret using a procedure similar to that for PI-A-ESi/P84-PES TFC hollow fiber membrane as described in Example 1, but PI-B polymer instead of PI-A is used for the sheath layer.
COMPARATIVE EXAMPLE 4
Preparation of PI-B/P84-PES polyimide TFC hollow fiber membrane
[0055] The PI-B/P84-PES TFC hollow fiber membrane comprising un-cross-linked PI-A polyimide is fabricated via a co-extrusion phase inversion spinning process from a sheath dope and a core dope using a triple-orifice spinneret using a procedure similar to that for PI- A/P84-PES TFC hollow fiber membrane as described in Comparable Example 1, but PI-B polymer instead of PI-A is used for the sheath layer.
EXAMPLE 5
Evaluation of CO2/CH4 separation performance of PI-B-ESi/P84-PES
and PI-B/P84-PES TFC hollow fiber membranes
[0056] The PI-B-ESi/P84-PES epoxysilicone-cross-linked polyimide TFC hollow fiber membrane and PI-B/P84-PES un-cross-linked polyimide TFC hollow fiber membrane were tested for CO2/CH4 separation at 50°C under 5617 kPa (800 psig) feed gas pressure with 10% of C02 and 90% of CH4 in the feed. The results are shown in Table 2. The PI-B-ESi/P84-PES epoxysilicone-cross-linked polyimide TFC hollow fiber membrane showed high C02/CH4 separation performance with CO2 permeance of 51 GPU and CO2/CH4 selectivity of 26.2 for CO2/CH4 separation at 50°C under 5617 kPa feed pressure with 10% C02 and 90% CH4 in the feed gas. The PI-B/P84-PES un-cross-linked polyimide TFC hollow fiber membrane showed higher CO2 permeance (69 GPU) and significantly lower CO2/CH4 selectivity (12.2) than the PI-B-ESi/P84-PES epoxysilicone-cross-linked polyimide TFC hollow fiber membrane even though the PI-B/P84-PES un-cross-linked polyimide TFC hollow fiber membrane has been coated with a thin layer of thermally cured RTV silicone. TABLE 2
CO2/CH4 separation performance of PI-B-ESi/P84-PES epoxysilicone cross-linked polyimide TFC hollow fiber membrane and PI-B/P84-PES un-cross-linked polyimide TFC hollow fiber membrane
Figure imgf000031_0002
1 GPU= 10"6 cm3 (STP)/cm2 s (cm Hg)
Testing conditions: 50°C, 5617 kPa (800 psig) feed gas pressure, 10% C02 and 90% of CH4 in the feed.
SPECIFIC EMBODFMENTS
While the following is described in conjunction with specific embodiments, it will be understood that this description is intended to illustrate and not limit the scope of the preceding description and the appended claims.
A first embodiment of the invention is a epoxysilicone-cross-linked polyimide membrane comprising an epoxysilicone-cross-linked polyimide polymer wherein the polyimide polymer comprises hydroxyl functional groups cross-linked with epoxy functional groups on the epoxysilicone polymer wherein the epoxysilicone-cross-linked polyimide olymer comprises a plurality of repeating units of formula (I), wherein formula (I) is
Figure imgf000031_0001
wherein R is selected from the group consisting of
MDxDEyQzTuDRfjDAkDPl(D (CH(R )CH20)m)nDBpM,
MEDxDEyQzTuDRfjDAkDPl(D (CH(R )CH20)m)nDBpME,
MEDxDEyQzTuDRfjDAkDPl(D (CH(R )CH20)m)nDBpM, and mixtures thereof; wherein M= (CH3)3Si01/2,
ME=
Figure imgf000032_0001
(CH3)2Si02/2,
= (CH3)3Si02/2,
Figure imgf000032_0002
DRf= (CF3CH2CH2)(CH3) Si02/2,
DA= ((HO)(C2H3)C6H9(CH2)2(CH3)Si02/2,
DP= ((HO)(C6H4)(CH2)3)(CH3)Si02/2,
DB= ((C6H5COO)(HO)(C6H9)(CH2)2)(CH3)Si02/2,
Q= Si04/2,
T= (CH3)3Si03/2,
wherein R is selected from the group consisting of hydrogen, methyl, and ethyl, and wherein j, k, 1, m, n, p, x, y, z, and u are positive integers and j, k, 1, n, p, u, and z may be zero;
wherein XI and X2 are selected from the group consisting of
Figure imgf000032_0003
and mixtures thereof, respectively; XI and X2 are the same or different from each other; wherein Yl is selected from the group consisting of
Figure imgf000033_0001
and mixtures thereof, R" is selected from the group consisting of
CF3 CH3 O
I I II
— ?— — ?— — i— — 0— — s—
CF3 CH3 O
and mixtures thereof, and R' " is selected from the group consisting of -H, COCH3, and mixtures thereof Y2 is selected from the group consisting of
Figure imgf000033_0002
and mixtures thereof, R" is selected from the group consisting
CF3 CH3 O
CF3 CH3 O
and mixtures thereof, and R" ' is selected from the group consisting of -H, COCH3, and mixtures thereof; and wherein a, b, and c are independent integers from 1 to 500. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the first embodiment in this paragraph wherein in formula (I), XI and X2 are selected from the group consisting of
Figure imgf000034_0001
and mixtures thereof, respectively; and XI and X2 are the same or different from each other. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the first embodiment in this paragraph wherein in formula (I), Yl is selected from the group consisting of
Figure imgf000034_0002
and mixtures thereof, wherein R" ' is selected from the group consisting of -H, COCH3, and mixtures thereof. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the first embodiment in this paragraph wherein in formula (I), Y2
Figure imgf000034_0003
wherein R' " is selected from the group consisting of -H, COCH3, and mixtures thereof. The epoxysilicone-cross-linked polyimide membrane of claim 1 wherein in formula (I), R is selected from the group consisting of MDxDEyM, MEDxDEyME, MEDxDEyM, and mixtures thereof; wherein
M= (CH3)3Si01/2,
ME=
Figure imgf000034_0004
(CH3)2Si02/2,
Figure imgf000035_0001
wherein x and y are positive integers. An embodiment of the invention is one, any or all prior embodiments in this paragraph up through the first embodiment in this paragraph wherein in formula (I), XI is
Figure imgf000035_0002
Figure imgf000035_0003
Yl is selected from the group consisting of
Figure imgf000035_0004
and mixtures thereof, and R' " is selected from the group consisting of -H, COCH3, and mixtures thereof. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the first embodiment in this paragraph is in a form selected from an asymmetric integrally skinned membrane, a thin film composite (TFC) membrane or a hollow fiber membrane. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the first embodiment in this paragraph wherein the thin film composite comprises a thin nonporous selective separation layer comprising an epoxysilicone-cross-linked polyimide polymer and a porous nonselective mechanical support layer made from a material different from the epoxysilicone-cross-linked polyimide polymer. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the first embodiment in this paragraph wherein the porous nonselective mechanical support layer comprises a polymer selected from the group consisting of polysulfones, sulfonated polysulfones, polyethersulfones, sulfonated polyethersulfones, polyethers, polyetherimides, cellulosic polymers such as cellulose acetate and cellulose triacetate, polyamides, polyimides, polyether ketones, and mixtures thereof An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the first embodiment in this paragraph wherein the polyimide polymer with hydroxyl functional groups comprises poly(2,2'-bis-(3,4-dicarboxyphenyl)hexafluoropropane dianhydride-3,3'- dihydroxy-4,4'-diamino-biphenyl-3,3'-diacetoxy-4,4'-diamino-biphenyl), poly(2,2'-bis-(3,4- dicarboxyphenyl)hexafluoropropane dianhydride-3,3'-dihydroxy-4,4'-diamino-biphenyl-3,3'- diacetoxy-4,4'-diamino-biphenyl-3,5-diaminobenzoic acid)
A second embodiment of the invention is a process for separating at least one gas from a mixture of gases using an epoxysilicone-cross-linked polyimide membrane
comprising an epoxysilicone-cross-linked polyimide polymer wherein the polyimide polymer comprises hydroxyl functional groups cross-linked with epoxy functional groups on the epoxysilicone polymer wherein the epoxysilicone-cross-linked polyimide polymer comprises a plurality of repeating units of formula (I), wherein formula (I) represented by a chemical structure
Figure imgf000036_0001
wherein R is selected from the group consisting of
MDxDEyQzTuDRf]DAkDPl(D (CH(R )CH20)m)nDBpM,
MEDxDEyQzTuDRfjDAkDPl(D (CH(R )CH20)m)nDBpME,
MEDxDEyQzTuDRfjDAkDPl(D (CH(R )CH20)m)nDBpM,
and mixtures thereof; wherein M= (CH3) 3Si01/2,
ME=
Figure imgf000037_0001
D= (CH3)2Si02/2,
D = (CH3) 3Si02/2,
DE =
Figure imgf000037_0002
DRf= (CF3CH2CH2)(CH3) Si02/2,
DA= ((HO)(C2H3)C6H9(CH2)2(CH3)Si02/2,
DP= ((HO)(C6H4)(CH2)3)(CH3)Si02/2,
DB= ((C6H5COO)(HO)(C6H9)(CH2)2)(CH3)Si02/2,
Q= Si04/2, T= (CH3)3Si03/2,
wherein R is selected from the group consisting of hydrogen, methyl, and ethyl, and wherein j, k, 1, m, n, p, x, y, z, and u are positive integers and j, k, 1, n, p, u, and z may be zero;
wherein XI and X2 are selected from the group consisting of
Figure imgf000037_0003
and mixtures thereof, respectively; XI and X2 are the same or different from each other; wherein Yl is selected from the group consisting of
and mixtures thereof, R" is selected from the group consisting of
CF3 CH3 O
I I II
— ? C—F3 — ? CH—3 — O I— — 0— — s—
and mixtures thereof, and R" ' is selected from the group consisting of -H, COCH3, and mixtures thereof Y2 is selected from the group consisting of
Figure imgf000038_0002
and mixtures thereof, R" is selected from the group consisting
F3 CH3 O
CF3 CH3 O
and mixtures thereof, and R" ' is selected from the group consisting of -H, COCH3, and mixtures thereof; and wherein a, b, and c are independent integers from 1 to 500, the process comprising (a) providing the epoxysilicone-cross-linked polyimide membrane described in the present invention which is permeable to the at least one gas; (b) contacting the mixture on one side of the epoxysilicone-cross-linked polyimide membrane to cause the at least one gas to permeate the membrane; and (c) removing from the opposite side of the membrane a permeate gas composition comprising a portion of the at least one gas which permeated the membrane. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the second embodiment in this paragraph wherein in formula (I), XI and X2 are selected from the group consisting of
Figure imgf000039_0001
and mixtures thereof, respectively; and XI and X2 are the same or different from each other. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the second embodiment in this paragraph wherein in formula (I), Yl is selected from th roup consisting of
Figure imgf000039_0002
and mixtures thereof, wherein R" ' is selected from the group consisting of -H, COCH3, and mixtures thereof. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the second embodiment in this paragraph wherein in formula (I), Y2 is
Figure imgf000039_0003
wherein R' " is selected from the group consisting of -H, COCH3, and mixtures thereof. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the second embodiment in this paragraph wherein in formula (I), R is selected from the group consisting of MDxDEyM, MEDxDEyME, MEDxDEyM, and mixtures thereof; wherein
M= (CH3)3Si01/2,
ME=
Figure imgf000040_0001
D= (CH3)2Si02/2,
DE =
Figure imgf000040_0002
wherein x and y are positive integers. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the second embodiment in this paragraph wherein in formula (I), XI is
Figure imgf000040_0003
Yl is selected from the group consisting of
Figure imgf000040_0004
and mixtures thereof, and R" ' is selected from the group consisting of -H, COCH3, and mixtures thereof. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the second embodiment in this paragraph wherein the mixture of gases is selected from the group consisting of volatile organic compounds in nitrogen or oxygen; carbon dioxide or hydrogen sulfide in natural gas; hydrogen, nitrogen, methane and argon; hydrogen in a mixture with hydrocarbons; olefins and paraffins; iso and normal paraffins; nitrogen and oxygen; carbon dioxide and methane; hydrogen and methane; carbon monoxide, helium and methane; and carbon dioxide, oxygen, nitrogen, water vapor, hydrogen sulfide, helium and other trace gases in raw natural gas. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the second embodiment in this paragraph wherein the mixture of gases is separated at a temperature from -20° to 100°C and a pressure from 275 kPa to 2.6 MPa. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the second embodiment in this paragraph wherein the mixture comprises hydrogen and methane. An embodiment of the invention is one, any or all of prior embodiments in this paragraph up through the second embodiment in this paragraph wherein the mixture comprises carbon dioxide in natural gas.
Without further elaboration, it is believed that using the preceding description that one skilled in the art can utilize the present invention to its fullest extent and easily ascertain the essential characteristics of this invention, without departing from the spirit and scope thereof, to make various changes and modifications of the invention and to adapt it to various usages and conditions. The preceding preferred specific embodiments are, therefore, to be construed as merely illustrative, and not limiting the remainder of the disclosure in any way whatsoever, and that it is intended to cover various modifications and equivalent arrangements included within the scope of the appended claims.
In the foregoing, all temperatures are set forth in degrees Celsius and, all parts and percentages are by weight, unless otherwise indicated.

Claims

1. An epoxysilicone-cross-linked polyimide membrane comprising an epoxysilicone- cross-linked polyimide polymer wherein the polyimide polymer comprises hydroxyl functional groups cross-linked with epoxy functional groups on the epoxysilicone polymer wherein said epoxysilicone-cross-linked polyimide polymer comprises a plurality of repeatin units of formula (I), wherein formula (I) is
Figure imgf000042_0001
wherein R is selected from the group consisting of
MDxDEyQzTuDRfjDAkDPl(D (CH(R )CH20)m)nDBpM,
MEDxDEyQzTuDRfjDAkDPl(D (CH(R )CH20)m)nDBpME,
MEDxDEyQzTuDRfjDAkDPl(D (CH(R )CH20)m)nDBpM,
and mixtures thereof; wherein
M= (CH3)3 Si01/2,
ME=
Figure imgf000042_0002
D= (CH3)2Si02/2,
D = (CH3)3 Si02/2,
DE =
Figure imgf000043_0001
DRf= (CF3CH2CH2)(CH3)Si02/2,
DA= ((HO)(C2H3)C6H9(CH2)2(CH3)Si02/2,
DP= ((HO)(C6H4)(CH2)3)(CH3)Si02/2,
DB= ((C6H5COO)(HO)(C6H9)(CH2)2)(CH3)Si02/2,
Q= Si04/2,
T= (CH3)3Si03/2,
wherein R is selected from the group consisting of hydrogen, methyl, and ethyl, and wherein j, k, 1, m, n, p, x, y, z, and u are positive integers and j, k, 1, n, p, u, and z may be zero; wherein XI and X2 are selected from the group consisting of
Figure imgf000043_0002
and mixtures thereof, respectively; XI and X2 are the same or different from each other wherein Yl is selected from the group consisting of
Figure imgf000043_0003
and mixtures thereof, R" is selected from the group consisting of
Figure imgf000044_0001
and mixtures thereof, and R' " is selected from the group consisting of -H, C0CH3, and mixtures thereof;Y2 is selected from the group consisting of
Figure imgf000044_0002
and mixtures thereof, R" is selected from the group consisting of
CF3 CH3 O
— ί— — ?— — i— — 0— — s—
CF3 CH3 O
and mixtures thereof, and R' " is selected from the group consisting of -H, COCH3, and mixtures thereof; and wherein a, b, and c are independent integers from 1 to 500.
2. The epoxysilicone-cross-linked polyimide membrane of claim 1 wherein in formula (I), XI and X2 are selected from the group consisting of
Figure imgf000044_0003
and mixtures thereof, respectively; and XI and X2 are the same or different from each other.
3. The epoxysilicone-cross-linked polyimide membrane of claim 1 wherein in formula (I), Yl is selected from the group consisting of
Figure imgf000044_0004
and mixtures thereof, wherein R' " is selected from the group consisting of -H, COCH3, and mixtures thereof.
4. The epoxysilicone-cross-linked polyimide membrane of claim 1 wherein in formula (I), Y2 is
Figure imgf000045_0001
wherein R' " is selected from the group consisting of -H, COCH3, and mixtures thereof.
5. The epoxysilicone-cross-linked polyimide membrane of claim 1 wherein in formula (I),R is selected from the group consisting of MDxDEyM, MEDxDEyME, MEDxDEyM, and mixtures thereof; wherein
M= (CH3)3Si01/2,
ME=
Figure imgf000045_0002
D= (CH3)2Si02/2,
DE
Figure imgf000045_0003
wherein x and y are positive integers.
6. The epoxysilicone-cross-linked polyimide membrane of claim 1 wherein in formul
Figure imgf000045_0004
Figure imgf000045_0005
Yl is selected from the group consisting of
Figure imgf000046_0001
and mixtures thereof, and R' " is selected from the group consisting of -H, COCH3, and mixtures thereof.
7. The epoxysilicone-cross-linked polyimide membrane of claim 1 is in a form selected from an asymmetric integrally skinned membrane, a thin film composite (TFC) membrane or a hollow fiber membrane.
8. A process for separating at least one gas from a mixture of gases using an epoxysilicone-cross-linked polyimide membrane according to any of claims 1-7,
the process comprising:
(a) providing said epoxysilicone-cross-linked polyimide membrane that is permeable to said at least one gas;
(b) contacting the mixture of gases to one side of said epoxysilicone-cross-linked polyimide membrane to cause said at least one gas to permeate the membrane; and
(c) removing from the opposite side of the membrane a permeate gas composition comprising a portion of said at least one gas which permeated said membrane.
9. The process of claim 8 wherein said mixture of gases is selected from the group consisting of volatile organic compounds in nitrogen or oxygen; carbon dioxide or hydrogen sulfide in natural gas; hydrogen, nitrogen, methane and argon; hydrogen in a mixture with hydrocarbons; olefins and paraffins; iso and normal paraffins; nitrogen and oxygen; carbon dioxide and methane; hydrogen and methane; carbon monoxide, helium and methane; and carbon dioxide, oxygen, nitrogen, water vapor, hydrogen sulfide, helium and other trace gases in raw natural gas.
10. The process of claim 8 wherein said mixture of gases is separated at a temperature from -20° to 100°C and a pressure from 275 kPa to 2.6 MPa.
PCT/US2016/021439 2015-03-18 2016-03-09 High selectivity epoxysilicone-cross-linked polyimide membranes for gas separations Ceased WO2016148988A1 (en)

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