HIFUNDA LLC — Department of Energy SBIR Phase I: 12a

Description

Membranes for gas separation represent a significant opportunity for reduced energy consumption and improved efficiencies in a wide range of industrial applications by replacing typical energy intensive processes with energy efficient processes. The ideal structure for carbon membranes is a mechanically robust porous support structure with a thin active membrane fabricated on the surface. While many different methods have been explored to fabricate this type of pore structure with partial success, problems such as cost, mechanical integrity and reliability still persist. In this project, HiFunda will develop and demonstrate a novel freeze casting process for fabrication of carbon membranes. This fabrication method is capable of producing high surface area membranes in both tubular and planar geometries with the desired membrane pore structure in a single phase monolithic and mechanically robust component. In the Phase I project, HiFunda will demonstrate the feasibility of the new fabrication method to create the desired pore structure. Laboratory scale performance testing will verify that gas separation performance is superior to literature reported values. In Phase II, HiFunda will scale up the process and the size of the membranes fabricated, and work with selected industrial partners to demonstrate the technology at pilot scale for specific applications. HiFunda will develop a novel membrane fabrication technology with the potential to lower energy costs, reduce toxic emissions and improve efficiencies for important industrial gas separation processes. The technology platform developed will find application across a broad range of industrial sectors resulting in improved energy efficiency and cleaner technology. Commercial Applications and Other Benefits: Highly efficient gas separation represents a key enabling technology for increasing efficiency and lowering cost in various applications involving advanced power generation systems, metallurgical operations and chemical processes. In addition to the target application of this proposal, namely oxygen separation from an air feed, carbon membranes have been shown to be effective at other important industrial gas separations such as CO2/CH4 and CO2/N2. The novel processing method proposed is capable of accurately controlling pore structure during the fabrication process opening the possibility to create a membrane technology platform that can operate across a broad range of gas compositions and applications. Membranes for gas separation represent a significant opportunity for reduced energy consumption and improved efficiencies in a wide range of industrial applications by replacing typical energy intensive processes with energy efficient processes. The ideal structure for carbon membranes is a mechanically robust porous support structure with a thin active membrane fabricated on the surface. While many different methods have been explored to fabricate this type of pore structure with partial success, problems such as cost, mechanical integrity and reliability still persist. In this project, HiFunda will develop and demonstrate a novel freeze casting process for fabrication of carbon membranes. This fabrication method is capable of producing high surface area membranes in both tubular and planar geometries with the desired membrane pore structure in a single phase monolithic and mechanically robust component. In the Phase I project, HiFunda will demonstrate the feasibility of the new fabrication method to create the desired pore structure. Laboratory scale performance testing will verify that gas separation performance is superior to literature reported values. In Phase II, HiFunda will scale up the process and the size of the membranes fabricated, and work with selected industrial partners to demonstrate the technology at pilot scale for specific applications. HiFunda will develop a novel membrane fabrication technology with the potential to lower energy costs, reduce toxic emissions and improve efficiencies for important industrial gas separation processes. The technology platform developed will find application across a broad range of industrial sectors resulting in improved energy efficiency and cleaner technology. Commercial Applications and Other Benefits: Highly efficient gas separation represents a key enabling technology for increasing efficiency and lowering cost in various applications involving advanced power generation systems, metallurgical operations and chemical processes. In addition to the target application of this proposal, namely oxygen separation from an air feed, carbon membranes have been shown to be effective at other important industrial gas separations such as CO2/CH4 and CO2/N2. The novel processing method proposed is capable of accurately controlling pore structure during the fabrication process opening the possibility to create a membrane technology platform that can operate across a broad range of gas compositions and applications.