J. Am. Ceram. Soc., 91 [1] 71–76 (2008)
DOI: 10.1111/j.1551-2916.2007.02073.x
r 2007 The American Ceramic Society
ournal
J
Relationship between the Mesoporous Intermediate Layer Structure
and the Gas Permeation Property of an Amorphous Silica Membrane
Synthesized by Counter Diffusion Chemical Vapor Deposition
w
Takayuki Nagano, Shinji Fujisaki, Koji Sato, Koji Hataya, and Yuji Iwamoto
Japan Fine Ceramics Center, Nagoya 456-8587, Japan
Mikihiro Nomura
Shibaura Institute of Technology, Tokyo 135-8548, Japan
Shin-Ichi Nakao
University of Tokyo, Tokyo 113-8656, Japan
An amorphous silica membrane with an excellent hydrogen/
nitrogen (H /N ) permselectivity of 410000 and a He/H perm-
bining these processes into a single step represent technical
1
–3
problems.
A membrane reactor has been investigated as a device for H
2
2
2
selectivity of 11 was successfully synthesized on a c-alumina
2
(
c-Al O )-coated a-alumina (a-Al O ) porous support by
mass production. It is well known that the application of high-
temperature membrane reactors to this steam-reforming step
has the potential of achieving the same conversion efficiencies as
those attained using conventional reactors at a significantly low
temperature of approximately 773 K. If a membrane with a high
durability under a steam atmosphere at elevated temperatures is
developed, these technical problems can be solved concurrently.
2
counter diffusion chemical vapor deposition using tetra-
3
2
3
methylorthosilicate and oxygen at 873 K. An amorphous silica
membrane possessed a high H permeance of 41.0 ꢀ 10
ꢁ
7
2
2
mol (m s Pa)
ꢁ1
.
mechanism for He and H at 373–873 K was activated diffu-
. .
at ꢂ 773 K. The dominant permeation
2
sion. On the other hand, that for CO , Ar, and N at 373–673 K
2
2
was a viscous flow. At ꢂ 673 K, that for CO , Ar, and N was
A palladium-based membrane with a high H permselectivity is
2
a candidate membrane reactor. However, there are some prob-
lems associated with the total cost of a resource.
An inorganic membrane with a high strength at elevated
temperatures and a high chemical stability is used under a high
pressure and corrosion atmosphere at elevated temperatures.
2
2
activated diffusion. H permselectivity was markedly affected by
2
the permeation temperature, thickness, and pore size of a
c-Al O mesoporous intermediate layer.
2
3
I. Introduction
Therefore, H production processes can be combined to sup-
2
press energy loss. An amorphous silica membrane is well known
as a H -permselective membrane. Amorphous silica membranes
YDROGEN (H
2
) has been attracting considerable attention as
2
H
a clean alternative energy source for fossil hydrocarbon
fuels. It is expected that H will be produced using natural
energies. However, it is difficult to meet the demand for H , and
H production through natural gas reforming has been investi-
2
gated. For example, methane (CH ), the main constituent of
4
4
are produced by sol–gel coating, chemical vapor deposition
,5
2
6
–14
(
CVD) and chemical vapor infiltration (CVI),
and precursor
In CVD and CVI, the surfaces of large
pores tend to be preferentially modified. Therefore, controlling
the formation of pinhole defects is easy, and a high H per-
meance to nitrogen (N ) (H /N permselectivity) has been
reported in membranes synthesized by CVD and CVI. For
2
1
5,16
polymer pyrolysis.
2
2
natural gas, is converted to H and carbon monoxide (CO)
through steam reforming as follows:
2
2
2
8
example, Tsapatsis et al. oxidized SiCl
2
glass by supplying H O gas and reported a H
4
gas on porous Vycor
/N permselectiv-
CH4 þ H2O ! 3H2 þ CO; DE ¼ 206 kJ=mol
(1)
2
2
1
2
ity of 5000 at 723 K. Nijimeijer et al. prepared a microporous
silica membrane on a mesoporous g-alumina (g-Al O )-coated
2
3
This reaction is endothermic and is induced at approximately
073 K. In this process, the synthesis gas then proceeds to a
a-alumina (a-Al
2
O
3
) porous support by low-temperature CVI
/N permselectivity of 440 at 523 K. Hwang
et al. prepared amorphous silica on a-Al porous tubes by
CVD using tetraethylorthosilicate and reported a H /N perm-
1
and reported a H
2
2
water–gas shift reactor where steam and CO can be converted
into H and carbon dioxide (CO ). Finally, H is separated from
1
3
2 3
O
2
2
2
2
2
the gas mixture using one of several adsorption technologies,
such as pressure swing adsorption. Owing to a high operation
temperature and several complex purification steps, the cost of
producing H with these current technologies is too high for it to
2
be used as an alternative source for conventional hydrocarbon
fuels. Therefore, decreasing the operation temperature and com-
1
4
selectivity of 160 at 873 K. Nomura et al. reported that a stable
amorphous silica membrane synthesized by counter diffusion
chemical vapor deposition (CDCVD) showed a H /N permse-
2
2
lectivity of 41000.
Inorganic membranes are composed of an active layer for
separating gas, an intermediate layer for suppressing the forma-
tion of pinhole defects on the active layer, and a porous support.
In the preparation of a microporous membrane by CVD and
CVI, the gas separation property strongly depends on the struc-
ture of the mesoporous intermediate layer. However, the rela-
tionship between the intermediate layer structure and gas
separation property has been reported in only a few papers.
T. Bessmann—contributing editor
Manuscript No. 23078. Received April 13, 2007; approved August 14, 2007.
This work was carried out as a part of the R&D Project on ‘‘Highly Efficient Ceramic
Membranes for High-Temperature Separation of Hydrogen’’ supported by the New Energy
and Industrial Technology Development Organization (NEDO), Japan.
13
Hwang et al. synthesized amorphous silica membranes on
w
a-Al O with an average pore size of 100 nm and g-Al O
3
2
3
2
7
1