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In this study, DDR membranes with a layer thickness of approximately 700 nm were studied for separation feeds comprising mixtures of CO 2 and CH 4. The membranes displayed the highest CO 2 over CH 4 permselectivity and CO 2 permeability reported in literature. This was ascribed to a defect-free and ultra-thin zeolite film as well as an open and highly permeable support. For equimolar mixtures, the highest CO 2 over CH 4 permselectivity of 727 was observed when the pressure at the feed side was 5 bar(a) and the permeate pressure was 1 bar(a) at 25 °C. At these conditions, the CO 2 permeability was very high at 45 × 10−7 mol/(m2 s Pa). Separation experiments for 80/20 and 20/80 mixtures were also performed, and in these cases, CO 2 over CH 4 permselectivities of 1011 and 622 were observed, respectively. For all feeds, the membrane permselectivity decreased slightly at higher temperature and in all cases, higher permselectivity was observed when vacuum was applied at the permeate side. One-stage membrane processes for upgrading biogas to biomethane at three different operating pressures were designed based on the experimental data. In all cases, a quite low membrane area, methane slip and power need were observed. [Display omitted] • DDR membranes with ultrahigh CO 2 permeance for CO 2 /CH 4 separation. • One-stage DDR membrane processes for biogas upgrading. • Low membrane area, CH 4 slip, and power use for these processes. [ABSTRACT FROM AUTHOR]

In the present work, single channel tubular zeolite CHA membranes with a length of 50 cm and a membrane area of 100 cm2 were evaluated by SEM and permeation experiments with single components and industrially relevant humid mixtures. The membranes comprised well-intergrown and smooth CHA films with a thickness of <500 nm supported on the inside of a highly porous tube. For single component permeation, a very low SF 6 permeance of 4.5 × 10−10 mol/(m2‧s‧Pa) was observed, which indicated nearly defect free membranes. On the contrary, the membranes displayed a very high CO 2 permeance of 128 × 10−7 mol/(m2‧s‧Pa), which illustrated the very high permeability of the CHA pores. Finally, the membranes displayed excellent selectivity for separation of industrially relevant CO 2 /CH 4 /H 2 O mixtures, which was attributed to selective interaction between the CO 2 molecules and the polar water molecules in the pores. The highest observed CO 2 /CH 4 separation selectivity was as high as 198 in combination with a CO 2 permeance of 14 × 10−7 mol/(m2‧s‧Pa) at a feed pressure of 600 kPa (including 2.2 kPa water) and 293K. The corresponding CO 2 flux was 0.39 mol/(m2‧s) and the corresponding CO 2 /CH 4 separation factor was 162. The observed membrane performance was reduced by concentration polarisation due to the limited feed flow in the experimental setup. The corresponding selectivity and CO 2 permeance corrected for concentration polarisation were as high as 236 and 16 × 10−7 mol/(m2‧s‧Pa), and the corrected CO 2 flux was 0.44 mol/(m2‧s) and corrected separation factor was 198. An estimate showed that even at a low feed pressure of 500 kPa, it would be sufficient with as few as 64 membranes for processing of a feed of 100 Nm3/h raw biogas, i.e. the capacity of a typical biogas plant at a large farm, to biomethane with high purity. These results illustrated that the membranes are promising candidates for industrial separation of CO 2 from e.g. natural gas and biogas. [Display omitted] • The first report described industrially relevant CHA membranes. • The membrane was a single channel tube with a membrane area of 100 cm2. • CO 2 single gas permeances was as high as 128 × 10−7 mol/(m2‧s‧Pa). • The highest observed CO 2 /CH 4 separation factor was 169. • Effect of concentration polarisation on separation was discussed. [ABSTRACT FROM AUTHOR]