Membrane fabrication methods using organosilica materials and uses thereof

Patent metadata

Field	Value
Publication number	US-10576453-B2
Application number	US-201514966445-A
Country	US
Kind code	B2
Filing date	Dec 11, 2015
Priority date	Dec 12, 2014
Publication date	Mar 3, 2020
Grant date	Mar 3, 2020

Abstract

Methods for fabricating a membrane with an organosilica material which is a polymer comprising independent units of Formula [Z3Z4SiCH2]3 (I), wherein each Z3 represents a hydroxyl group, a C1-C4 alkoxy group or an oxygen atom bonded to a silicon atom of another unit or an active site on the support and each Z4 represents a hydroxyl group, a C1-C4 alkoxy group, a C1-C4 alkyl group, an oxygen atom bonded to a silicon atom of another unit or an active site on the support are provided. Methods of removing a contaminant from a hydrocarbon stream are also provided.

First claim

What is claimed is:

1. A method for fabricating a membrane, the method comprising:
(a) adding at least one cyclic compound of Formula [Z 1 Z 2 SiCH 2 ] 3 (Ia) into an aqueous mixture to form a solution, wherein the aqueous mixture and the solution contain essentially no structure directing agent or porogen and wherein the aqueous mixture comprises an acid and has a pH from about 0.01 to about 6.0, each Z 1 represents a C 1 -C 4 alkoxy group and each Z 2 represents, a C 1 -C 4 alkoxy group or a C 1 -C 4 alkyl group; wherein the solution contains about 5.1 to about 5.4 wt. % of the compound of Formula (Ia) based on the total weight of the solution; adding a C 1 -C 4 alcohol to the solution;
(b) coating the solution onto a support, wherein the support is a ceramic support, a polymer support, a mixed-matrix support, a metallic support, a silica support, a carbon support, a liquid/facilitated transport support, a zeolite support, or combinations thereof, to form a coated support;
(c) aging the coated support; and
(d) drying the coated support to obtain a membrane comprising an organosilica material which is a polymer comprising independent units of Formula [Z 3 Z 4 SiCH 2 ] 3 (I), wherein each Z 3 represents a hydroxyl group or an oxygen atom bonded to a silicon atom of another unit or an active site on the support and each Z 4 represents a hydroxyl group or an oxygen atom bonded to a silicon atom of another unit or an active site on the support, wherein the organosilica material has an X-ray diffraction spectrum exhibiting substantially no peaks above 6 degrees 2θ.

2. The method of claim 1 , wherein each Z 1 represents a C 1 -C 2 alkoxy group.

3. The method of claim 2 , wherein each Z 2 represents a C 1 -C 4 alkoxy group.

4. The method of claim 3 , wherein each Z 2 represents a C 1 -C 2 alkoxy group.

5. The method of claim 1 , wherein the at least one compound of Formula (Ia) is 1,1,3,3,5,5-hexaethoxy-1,3,5-trisilacyclohexane.

6. The method of claim 1 , further comprising adding to the aqueous mixture at least a second compound selected from the group consisting of:
(i) a further compound of Formula (Ia);
(ii) a compound of Formula R 1 OR 2 R 3 R 4 Si (II), wherein each R 1 represents a C 1 -C 4 alkyl group; and R 2 , R 3 , and R 4 are each independently selected from the group consisting of a C 1 -C 4 alkyl group, a C 1 -C 4 alkoxy group, a nitrogen-containing C 1 -C 10 alkyl group, a nitrogen-containing heteroalkyl group, and a nitrogen-containing optionally substituted heterocycloalkyl group;
(iii) a compound of Formula Z 5 Z 6 Z 7 Si—R—SiZ 5 Z 6 Z 7 (III), wherein each Z 5 independently represents a C 1 -C 4 alkoxy group; each Z 6 and Z 7 independently represent a C 1 -C 4 alkoxy group or a C 1 C 4 alkyl group; and R is selected from the group consisting a C 1 -C 8 alkylene group, a C 2 -C 8 alkenylene group, a C 2 -C 8 alkynylene group, a nitrogen-containing C 1 -C 10 alkylene group, an optionally substituted C 6 -C 20 aralkyl and an optionally substituted C 4 -C 20 heterocycloalkyl group;
(iv) a compound of Formula M 1 (OZ 8 ) 3 (IV), wherein M 1 represents a Group 13 metal and each Z 8 independently represents a C 1 -C 6 alkyl;
(v) a compound of Formula)(Z 9 O) 2 M 2 —O—Si(OZ 10 ) 3 (V) , wherein M 2 represents a Group 13 metal and Z 9 and Z 10 each independently represent a C 1 -C 6 alkyl group;
(vi) a cyclic compound of Formula

 wherein each R 1 independently is a X 1 OX 2 X 3 SiX 4 group, wherein each X 1 represents a C 1 -C 4 alkyl group; X 2 and X 3 each independently represent a C 1 -C 4 alkyl group, a C 1 -C 4 alkoxy group; and X 4 represents a C 1 -C 8 alkylene group bonded to a nitrogen atom of the cyclic compound; and
(vii) a combination thereof.

7. The method of claim 6 , wherein the second compound is a compound of Formula (Ia), wherein each Z 1 represents a C 1 -C 2 alkoxy group and each Z 2 represents C 1 -C 2 alkoxy group or a C 1 -C 2 alkyl group.

8. The method of claim 7 , wherein the compound of Formula (Ia) is 1,3,5-trimethyl-1,3,5-triethoxy-1,3,5-trisilacyclohexane.

9. The method of claim 6 , wherein the second compound is a compound of Formula (II), wherein each R 1 represents a C 1 -C 2 alkyl group and R 2 , R 3 , and R 4 are each independently a C 1 -C 2 alkyl group, C 1 -C 2 alkoxy group, a nitrogen-containing C 3 -C 10 alkyl group, a nitrogen-containing C 4 -C 10 heteroaralkyl group, or a nitrogen-containing optionally substituted C 4 -C 10 heterocycloalkyl group.

10. The method of claim 9 , wherein the compound of Formula (II) is selected from the group consisting of tetraethyl orthosilicate, methyltriethoxysilane, (N,N-dimethyl-aminopropyl)trimethoxysilane, N-(2-aminoethyl)-3-aminopropyltriethoxysilane, 4-methyl-1-(3-triethoxysilylpropyl)-piperazine, 4-(2-(triethoxysily)ethyl)pyridine, 1-(3-(triethoxysilyl)propyl)-4,5-dihydro-1H-imidazole, and (3-aminopropyl)triethoxysilane.

11. The method of claim 6 , wherein the second compound is a compound of Formula (III), wherein Z 5 represents a C 1 -C 2 alkoxy group; each Z 6 and Z 7 independently represent a C 1 -C 2 alkoxy group, or a C 1 -C 2 alkyl group; and R is selected from the group consisting of a C 1 -C 4 alkylene group, a C 2 -C 4 alkenylene group, a C 2 -C 4 alkynylene group, and a nitrogen-containing C 4 -C 10 alkylene group.

12. The method of claim 11 , wherein the compound of Formula (III) is selected from the group consisting of 1,2-bis(methyldiethoxysilyl)ethane, bis(triethoxysilyl)methane, 1,2-bis-(triethoxysilyl)ethylene, N,N′-bis [(3-trimethoxysilyl)propyl]ethylenediamine, bis[(methyl-diethoxysilyl)propyl]amine, and bis[(methyldimethoxysilyl)propyl]-N-methylamine.

13. The method of claim 6 , wherein the second compound is a compound of Formula (IV), wherein M 1 is Al or B and each Z 8 represents a C 1 -C 4 alkyl group.

14. The method of claim 6 , wherein the second compound is a compound of Formula (V), wherein M 2 is Al or B; and Z 9 and Z 10 each independently represent a C 1 -C 4 alkyl group.

15. The method of claim 13 , wherein the second compound is selected from the group consisting of aluminum trimethoxide, aluminum triethoxide, aluminum isopropoxide, and aluminum-tri-sec-butoxide.

16. The method of claim 6 , wherein the second compound is a compound of Formula (VI), wherein each X 1 represents a C 1 -C 2 alkyl group; X 2 and X 3 each independently represent a C 1 -C 2 alkyl group or a C 1 -C 2 alkoxy group; and each X 4 represents a C 1 -C 4 alkylene group bonded to a nitrogen atom of the cyclic compound.

17. The method of claim 16 , wherein the compound of Formula (VI) is tris(3-trimethoxysilylpropyl)isocyanurate.

18. The method of claim 1 , wherein the aqueous mixture comprises a base and has a pH from about 8 to about 15.

19. The method of claim 18 , wherein the base is ammonium hydroxide or a metal hydroxide.

20. The method of claim 1 , wherein the acid is an inorganic acid.

21. The method of claim 1 , wherein the inorganic acid is hydrochloric acid.

22. The method of claim 1 , wherein the coated support is aged for up to 144 hours at a temperature of about room temperature 20° C. to about 200° C.

23. The method of claim 1 , wherein the coated support is dried at a temperature of about 15° C. to about 200° C.

24. The method of

Assignees

• Exxonmobil Res & Eng Co

Inventors

• Li Quanchang
• Bhandari Dhaval Ajit
• Mccool Benjamin A

Classifications

• B01J20/3236

  containing metal, other than zeolites, e.g. oxides, hydroxides, sulphides or salts · CPC title

• B01J20/0237

  Compounds of Cu · CPC title

• B01J20/28061

  being in the range 100-500 m2/g · CPC title

• B01J20/3204

  Inorganic carriers, supports or substrates · CPC title

• B01J31/0274

  containing silicon (ligands in coordination complexes B01J31/1608) · CPC title