# US 11,305,240 B2 · Zeolite membrane complex and method of producing zeolite membrane complex

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- Number: US 11,305,240 B2
- Document ID: US11305240B2
- Status: Granted
- Kind: B2
- Application number: 16/899,981
- Filed: 2020-06-12
- Published: 2020-10-01
- Granted: 2022-04-19
- Earliest claimed: 2018-01-16
- Assignees: NGK Insulators, Ltd.
- Applicants: Ngk Insulators, Ltd.
- Inventors: Kenichi Noda; Aya Miura; Ryotaro Yoshimura
- Web page: https://patentgrep.com/patent/US11305240B2

## CPC

- B01D 71/0281: {Zeolites}
- B01D 53/228: {characterised by specific membranes}
- B01D 67/0051: {by controlled crystallisation, e,.g. hydrothermal growth}
- B01D 69/108: {Inorganic support material}
- B01D 69/1213: {Laminated layers}
- C01B 39/54: Phosphates, e.g. APO or SAPO compounds
- B01D 2256/22: Carbon dioxide
- B01D 2257/504: Carbon dioxide
- B01D 2323/24: Use of template or surface directing agents [SDA]
- Y02C 20/40: of CO2
- Y02P 20/151: Reduction of greenhouse gas [GHG] emissions, e.g. CO2
- B01D: SEPARATION (separating solids from solids by wet methods B03B, B03D; by pneumatic jigs or tables B03B; by other dry methods B07; magnetic or electrostatic separation of solid materials from solid materials or fluids, separation by high-voltage electric fields B03C; centrifuges, vortex apparatus B04; presses per se for squeezing-out liquid from liquid-containing material B30B9/02; treatment of water C02F, e.g. softening by ion-exchange C02F1/42; {arrangements of air intake cleaners in gas turbine plants F02C7/05} ; arrangements or mounting of filters in air-conditioning, air-humidification or ventilation F24F13/28)
- C01B: NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; {METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C}
- Y02C: CAPTURE, STORAGE, SEQUESTRATION OR DISPOSAL OF GREENHOUSE GASES [GHG]
- Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS

## Abstract

A zeolite membrane complex includes a support and a zeolite membrane formed on the support. The zeolite membrane is of an SAT-type zeolite. Among particles on the surface of the zeolite membrane, particles that have aspect ratios higher than or equal to 1.2 and lower than or equal to 10 account for 85% or more of the area of the surface of the zeolite membrane. This improves the orientations of the particles and also reduces the interstices among the particles. As a result, the denseness of the zeolite membrane is improved. Accordingly, for example, high gas separation performance can be obtained when the zeolite membrane complex is used as a gas separation membrane.

## Claims

### Claim 1

A zeolite membrane complex comprising:
a support; and
a zeolite membrane formed on said support;
wherein said zeolite membrane is of an SAT-type zeolite, and
among particles on a surface of said zeolite membrane facing away from said support, particles that have aspect ratios higher than or equal to 1.2 and lower than or equal to 10 account for 85% or more of an area of said surface of said zeolite membrane.

### Claim 2 (depends on 1)

The zeolite membrane complex according to claim 1, wherein
an average value of aspect ratios of said particles on said surface of said zeolite membrane is greater than or equal to 1.4 and less than or equal to 4.

### Claim 3 (depends on 1)

The zeolite membrane complex according to claim 1, wherein said support is porous.

### Claim 4 (depends on 1)

The zeolite membrane complex according to claim 1, wherein
said support is an alumina sintered compact or a mullite sintered compact.

### Claim 5

A method of producing a zeolite membrane complex, comprising:
a) synthesizing an SAT-type zeolite by hydrothermal synthesis and obtaining seed crystals from said SAT-type zeolite;
b) depositing said seed crystals on a support;
c) immersing said support in a starting material solution having a pH greater than or equal to 5 and less than or equal to 8, and growing an SAT-type zeolite from said seed crystals by hydrothermal synthesis to form a zeolite membrane on said support, the starting material solution being prepared by mixing an aluminum source and a phosphorus source with a PH greater than or equal to 4; and
d) removing a structure-directing agent from said zeolite membrane,
wherein, among particles on a surface of said zeolite membrane facing away from said support, particles that have aspect ratios higher than or equal to 1.2 and lower than or equal to 10 account for 85% or more of an area of said surface of said zeolite membrane.

### Claim 6 (depends on 5)

The method of producing a zeolite membrane complex according to claim 5, wherein
an average value of aspect ratios of said particles on said surface of said zeolite membrane is greater than or equal to 1.4 and less than or equal to 4.

### Claim 7 (depends on 5)

The method of producing a zeolite membrane complex according to claim 5, wherein
in said operation a) or c), aluminum alkoxide or an alumina sol is used as the aluminum source in the hydrothermal synthesis.