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In this study, six different types of polysulfone hollow fiber membranes were fabricated from the same polymeric dope solution by manipulating several important parameters during the spinning process, aiming to find the best membrane supports for the coating layer in the gas separation process. The experimental results showed that upon the polydimethylsiloxane (PDMS) coating process, the gas pair selectivities of all six types of membranes were significantly increased with respect to carbon dioxide (CO2)/methane (CH4) and oxygen (O2)/nitrogen (N2) separation. However, the membrane support spun at higher air gap and lower dope extrusion rate was found to be the best support for PDMS coating owing to its good structural integrity that led to a good balance between gas permeance and gas pair selectivity. Further investigation showed that the use of poly(ether block amide) (Pebax) as coating material did not certainly improve both gas permeance and the selectivity of hollow fiber membranes, although Pebax was previously reported to exhibit better performance than PDMS in flat sheet membranes. One of the main reasons is the difficulty of forming a defect-free Pebax coating layer on the outer surface of hollow fibers owing to the stickiness issue among fibers upon coating. More research is still needed to optimize the Pebax coating solution and its drying process in order to achieve the full potential of such coating material for hollow fiber membranes.

Asymmetric mixed matrix membranes (MMMs) incorporating Cloisite15A (C15A) clay particles were prepared using solvent evaporation and phase inversion with polyethersulfone (PES) as the membrane matrix. C15A loadings varied at 1 wt% and 5 wt%. Membrane morphological and thermal properties were evaluated by means of X-ray diffraction (XRD), scanning electron microscopy (SEM), thermogravimetric analysis (TGA) and differential scanning calorimetry (DSC). Addition of the C15A favorably altered the microscopic structure of membranes from finger-like to homogeneous sponge-like structure as the loading increased. While the amorphous nature of MMMs was retained, the thermal stability was also found to be improved with a slight decrease in glass transition temperature (T g). PES/C15A1 MMM showed the best gas transport properties, with 37% and 65% improvement in CO2 permeance and CO2/CH4 selectivity, respectively. Unlike 1 wt%, the loss in selectivity shown by 5 wt% clay loadings suggested that the interphase voids and extent of silicate layers dispersion play a significant role in the overall performance of MMMs.