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A membrane reactor is a device for simultaneously performing a reaction and a membrane-based separation in the same physical device. Therefore, the membrane not only plays the role of a separator, but also takes place in the reaction itself.
This text covers, in detail, the preparation and characterisation of all types of membranes used in membranes reactors. Each membrane synthesis process used by membranologists is explained by well known scientists in their specific research field.
The book opens with an exhaustive review and introduction to membrane reactors, introducing the recent advances in this field. The following chapters concern the preparation of both organic and inorganic, and in both cases, a deep analysis of all the techniques used to prepare membrane are presented and discussed. A brief historical introduction for each technique is also included, followed by a complete description of the technique as well as the main results presented in the international specialized literature. In order to give to the reader a summary look to the overall work, a conclusive chapter is included for collecting all the information presented in the previous chapters.
Key features:
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Contents
Cover
Title Page
Copyright
Contributors
Glossary
Greek Symbols
Subscripts or Superscripts
Acronyms
Introduction – A Review of Membrane Reactors
1 Introduction
2 Membranes for Membrane Reactors
3 Salient Features of Membrane Reactors
4 Hydrogen Production by Membrane Reactors
5 Other Examples of Membrane Reactors
6 Membrane Bioreactor
7 Conclusion
References
Chapter 1: Microporous Carbon Membranes
1.1 Introduction
1.2 Transport Mechanisms in Carbon Membranes
1.3 Methods for the Preparation of Microporous Carbon Membranes
1.4 Membrane Modules
1.5 Applications of Membranes in Membrane Reactor Processes
1.6 Final Remarks and Conclusions
References
Chapter 2: Metallic Membranes by Wire Arc Spraying: Preparation, Characterisation and Applications
2.1 Introduction
2.2 Thermal Spraying
2.3 Preparation of Membranes
2.4 Characterisation of Prepared Metallic Membrane
2.5 Applications of Prepared Metallic Membrane
2.6 Final Remarks and Conclusions
References
Chapter 3: Inorganic Hollow Fibre Membranes for Chemical Reaction
3.1 Introduction
3.2 Preparation of Inorganic Hollow Fibre Membranes
3.3 Coating of Pd/Ag Membranes
3.4 Catalyst Impregnation
3.5 Application in Chemical Reaction
3.6 Final Remarks and Conclusions
3.7 Acknowledgements
References
Chapter 4: Metallic Membranes Prepared by Cold Rolling and Diffusion Welding
4.1 Introduction
4.2 Preparation Method
4.3 Applications
4.4 Conclusions
References
Chapter 5: Preparation and Synthesis of Mixed Ionic and Electronic Conducting Ceramic Membranes for Oxygen Permeation
5.1 Introduction
5.2 Preparation of MIEC Ceramic Powders
5.3 Preparation of MIEC Membranes
5.4 Example Applications of MIEC Membranes for the Partial Oxidation of Methane
5.5 Final Remarks and Conclusions
5.6 Acknowledgements
References
Chapter 6: Nanostructured Perovskites for the Fabrication of Thin Ceramic Membranes and Related Phenomena
6.1 Introduction
6.2 Support
6.3 Selection of Ceramics with High Oxygen Mobility
6.4 Synthesis of Ceramics with Required Ts and a High Oxygen Permeability
6.5 Combination of Compatible Materials and Operations
6.6 Design of Catalyst for Selective Reforming of Methane to Syngas
6.7 Conclusion
6.8 Acknowledgement
References
Chapter 7: Nanostructured Perovskites for the Fabrication of Thin Ceramic Membranes and Related Phenomena
Introduction
7.2 Experimental
7.3 Results and Discussion
7.4 Conclusion
7.5 Acknowledgement
References
Chapter 8: Zeolite Membrane Reactors
8.1 Introduction
8.2 Zeolite Membrane Preparation Outlines
8.3 Detailed Preparation Method of a Zeolite Membrane
8.4 Types of Zeolite Membrane Reactors
8.5 Concluding Remarks
References
Chapter 9: Metal Supported and Laminated Pd-Based Membranes
9.1 Introduction
9.2 Preparation Method
9.3 Applications
9.4 Conclusions
References
Chapter 10: PVD Techniques for Metallic Membrane Reactors
10.1 Introduction
10.2 Physical Vapour Deposition Techniques
10.3 Pd-Based Metallic Membranes
10.4 Conclusions
References
Chapter 11: Membranes Prepared via Electroless Plating
11.1 Introduction
11.2 Description of the Electroless Plating Process
11.3 Morphology of Palladium Deposits
11.4 Pd-Alloy Preparation
11.5 Membrane Performances and Integration in Membrane Reactors
11.6 Conclusions
References
Chapter 12: Silica Membranes – Preparation by Chemical Vapour Deposition and Characteristics
12.1 Introduction
12.2 Fundamentals of Chemical Vapour Deposition
12.3 CVD Apparatus
12.4 Silica H-Membranes Produced by CVD
12.5 Silica Membrane Structure and Transport Mechanism
12.6 Hydrothermal Stability of Silica Membranes
12.7 Examples of Silica Membrane Application
12.8 Conclusions
References
Chapter 13: Membranes Prepared via Molecular Layering Method
13.1 Introduction
13.2 Molecular Layering: Principles, Synthesis Possibilities and Fields of Application
13.3 Optimisation of MR Structure and Catalytic Properties by the ML Method
References
Chapter 14: Solvated Metal Atoms in the Preparation of Catalytic Membranes
14.1 Introduction
14.2 Preparation of Catalytic Membranes
14.3 Catalytic Exploitation
14.4 Conclusions
References
Chapter 15: Electrophoretic Deposition for the Synthesis of Inorganic Membranes
15.1 Introduction
15.2 State of the Art
15.3 Experimental
15.4 Discussion and Applications
15.5 Conclusions
15.6 Acknowledgements
References
Chapter 16: Electrochemical Preparation of Nanoparticle Deposits: Application to Membranes and Catalysis
16.1 Introduction
16.2 State of the Art
16.3 Experimental
16.4 Discussion and Applications
16.5 Conclusions
16.6 Acknowledgements
References
Chapter 17: Electrochemical Preparation of Pd Seeds/Inorganic Multilayers on Structured Metallic Fibres
17.1 Introduction
17.2 Brief Review on Preparation Method
17.3 Explanation of the Proposed Preparation Method
17.4 Multilayer Preparation on Metal Substrates
17.5 Final Remarks and Conclusion
References
Chapter 18: Membranes Prepared Via Spray Pyrolysis
18.1 Introduction
18.2 Spray Pyrolysis Material Preparation Method
18.3 Selected Membranes Prepared Via Spray Pyrolysis Coating Method
18.4 Catalyst Synthesis and Spread in PEMFC
18.5 Remarks and Perspectives
18.6 Acknowledgements
References
Chapter 19: Silica Membranes – Preparation and Characterisation of Nanocrystalline and Quasicrystalline Alloys by Planar Flow Casting for Metal Membranes
19.1 Introduction
19.2 Properties and Preparation of Nanocrystalline and Quasicrystalline Metals
19.3 Preparation of Nanocrystalline and Quasicrystalline Metal Membranes by Planar Flow Casting
19.4 Nanocrystalline and Quasicrystalline Metal Membranes for Hydrogen Separation
19.5 Concluding Remarks
References
Chapter 20: Silica Membranes – Preparation and Characterisation of Amorphous Alloy Membranes
20.1 Introduction
20.2 Brief Review of Preparation Methods
20.3 Experimental Procedure
20.4 Hydrogen Permeation of Ni-Nb-Zr Amorphous Alloy Membranes
20.5 Hydrogen Production by Methanol Steam Reforming Using Melt-Spun Ni-Nb-Ta-Zr-Co Amorphous Alloy Membrane
20.6 Final Remarks and Conclusions
References
Chapter 21: Membranes Prepared Via Phase Inversion
21.1 Introduction
21.2 Brief Review
21.3 Explanation of the Phase Inversion Process
21.4 Some Applications
21.5 Conclusions
References
Chapter 22: Porous Flat Sheet, Hollow Fibre and Capsule Membranes by Phase Separation of Polymer Solutions
22.1 Introduction
22.2 Porous Polymeric Membranes Classification
22.3 Polymers for Porous Membranes
22.4 Polymeric Membrane Preparation Via Phase Separation
22.5 Industrial Manufacturing of Porous Polymeric Membranes
22.6 Applications in Membrane Reactor Processes
22.7 Conclusions and Outlook
References
Chapter 23: Porous Polymer Membranes by Manufacturing Technologies other than Phase Separation of Polymer Solutions
23.1 Introduction
23.2 Technologies Based on Extrusion of Polymer Films
23.3 Electrospinning of Porous Polymer Membranes
23.4 In Situ Polymerisation of Porous Membranes
23.5 Surface and Pore Functionalised Membranes
23.6 Overview on Technical Porous Polymeric Membranes
23.7 Applications in Membrane Reactor Processes
23.8 Conclusions and Outlook
23.9 Acknowledgements
References
Chapter 24: Palladium-Loaded Polymeric Membranes for Hydrogenation in Catalytic Membrane Reactors
24.1 Introduction
24.2 Synthesis and Hydrogenation Studies
24.3 Characterisation of Palladium Nanoparticles in Catalytic Membranes
24.4 Kinetic Studies
24.5 Conclusions
24.6 Acknowledgement
References
Chapter 25: Membrane Prepared via Plasma Modification
25.1 Introduction
25.2 Membrane Treatment with Microwave Plasma
25.3 Modes of Plasma Use
25.4 Plasma of Nonpolymerisable Gas
25.5 Plasma of Polymerisable Species
25.6 Plasma-Induced Grafting
References
Chapter 26: Enzyme-Immobilised Polymer Membranes for Chemical Reactions
26.1 Introduction
26.2 Brief Review of the Preparation Method of Enzyme-Immobilised Polymer Membranes
26.3 Preparation of Enzyme-Immobilised Polymer Membranes
26.4 Applications of Enzyme-Immobilised Polymer Membranes as Membrane Reactors
26.5 Final Remarks and Conclusions
References
Final Remarks
1 Introduction
2 Membranes for Membrane Reactors
3 Epilogue
References
Color Plates
Index
This edition first published 2011
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Library of Congress Cataloging-in-Publication Data
Membranes for membrane reactors : preparation, optimization, and selection / [edited by] Angelo Basile, Fausto Gallucci.
p. cm.
Includes bibliographical references and index.
ISBN 978-0-470-74652-3 (hardback)
1. Membrane reactors. I. Basile, Angelo (Angelo Bruno) II. Gallucci, Fausto.
TP248.25.M45M46 2011
6600′.2832–dc22
2010044313
A catalogue record for this book is available from the British Library.
Print ISBN: 9780470746523
ePDF ISBN 9780470977552
oBook ISBN: 9780470977569
ePub ISBN: 9780470977576
Contributors
J. Arias-Pardilla, Centro de Electroquímica y Materiales Inteligentes, Universidad Politécnica de Cartagena, Cartagena, Spain
A. Basile, Institute on Membrane Technology, CNR, c/o University of Calabria, Rende, CS, Italy
F. Basile, Università di Bologna, Bologna, Italy
N. L. Basov, Topchiev Institute of Petrochemical Synthesis, Moscow, Russia
P. Benito, Università di Bologna, Bologna, Italy
A. Berenguer-Murcia, Universidad de Alicante, Departamento de Química Inorgánica, Alicante, Spain
M. Broglia, ERSE S.p.A., Milano, Italy
R. S. Brusa, Dipartimento di Fisica, Università di Trento, Trento, Italy
M. Bryjak, Department of Polymer and Carbon Materials, Wroclaw University of Technology, Wroclaw, Poland
M. G. Buonomenna, Department of Material and Chemical Engineering, University of Calabria and Consortium INSTM, Rende, CS, Italy
G. Capannelli, Department of Chemistry and Industrial Chemistry, University of Genoa, Genoa, Italy
D. Cazorla-Amorós, Universidad de Alicante, Departamento de Química Inorgánica, Alicante, Spain
R. Checchetto, Dipartimento di Fisica, Università di Trento, TN, Italy
S.-H. Choi, Institute on Membrane Technology, ITM-CNR, c/o University of Calabri, Rende, CS, Italy; and Green Chemistry and Environmental Biotechnology, University of Science and Technology, Daejeon, Korea
P. Daraei, Membrane Research Center, Department of Chemical Engineering, Razi University, Kermanshah, Iran
E. Drioli, Institute on Membrane Technology/Department of Material and Chemical Engineering, ITM-CNR, c/o University of Calabria, Rende CS Italy
S. D. Dubrovensky, St. Petersburg State Institute of Technology, St. Petersburg, Russia
M. M. Ermiloa, Topchiev Institute of Petrochemical Synthesis, Moscow, Russia
C. Evangelisti, Department of Chemistry and Industrial Chemistry, University of Pisa, Pisa, Italy
G. Fornasari, Università di Bologna, Bologna, Italy
F. Galiano, Institute on Membrane Technology, ITM-CNR, c/o University of Calabria, Rende CS, Italy
F. Gallucci, Chemical Process Intensification, Faculty of Chemical Engineering and Chemistry, Eindhoven University of Technology, Eindhoven, The Netherlands
J. Galuszka, Natural Resources Canada, CanmetENERGY, Ontario, Canada
I. Gancarz, Department of Polymer and Carbon Materials, Wroclaw University of Technology, Wroclaw, Poland
M. A. Gibson, CSIRO Materials Science and Engineering, Clayton, Victoria, Australia
T. Giddings, Natural Resources Canada, CanmetENERGY, Ontario, Canada
L. Guo, State Key Laboratory of Multiphase Flow in Power Engineering, Xi'an Jiaotong University, Xi'an, PR China
F. I. Hai, Environmental Engineering, The University of Wollongong, New South Wales, Australia
K. Haraya, Research Institute for Innovation in Sustainable Chemistry, National Institute of Advanced Industrial Science and Technology, Tsukuba, Japan
A. Inoue, Institute for Materials Research, Tohoku University, Sendai, Japan.
B. F. K. Kingsbury, Department of Chemical Engineering, Imperial College London, London, UK
S. Kurungot, Physical and Materials Chemistry Division, National Chemical Laboratory, Pune, India
V.I. Lebedeva, Topchiev Institute of Petrochemical Synthesis, Russian Academy of Sciences, Moscow, Russia
K. Li, Department of Chemical Engineering, Imperial College London, London, UK
M. Li, State Key Laboratory of Multiphase Flow in Power Engineering, Xi'an Jiaotong University, Xi'an, PR China
A. Linares-Solano, Universidad de Alicante, Departamento de Química Inorgánica, Alicante, Spain
S. S. Madaeni, Membrane Research Center, Department of Chemical Engineering, Razi University, Kermanshah, Iran
A. A. Malkov, St. Petersburg State Institute of Technology, St. Petersburg, Russia
A. A. Malygin, St. Petersburg State Institute of Technology, St. Petersburg, Russia
M. Menéndez, Aragón Institute of Engineering Research, University of Zaragoza, Zaragoza, Spain
S. V. Mikhaylovskiy, St. Petersburg State Institute of Technology, St. Petersburg, Russia
A. Miotello, Dipartimento di Fisica, Università di Trento, Trento, Italy
M. Monti, Università di Bologna, Bologna, Italy
E. Morallón, Universidad de Alicante, Departamento de Química Física and Instituto Universitario de Materiales, Alicante, Spain
A. P. Nemudry, Institute of Solid State Chemistry and Mechanochemistry, SB RAS, Novosibirsk, Russia
R. O'Hayre, Metallurgical and Materials Engineering, Colorado School of Mines, Golden, Colorado, USA
N. V. Orekhova, Topchiev Institute of Petrochemical Synthesis, Moscow, Russia
N. Panziera, Department of Chemistry and Industrial Chemistry, University of Pisa, Pisa, Italy
I. V. Petrova, Topchiev Institute of Petrochemical Synthesis, Russian Academy of Sciences, Moscow, Russia
J. W. Phair, Division of Fuel Cells and Solid State Chemistry, Ris National Laboratory for Sustainable Energy, The Technical University of Denmark, Roskilde, Denmark
P. Pinacci, ERSE S.p.A., Milano, Italy
E. Pitzalis, CNR, Institute of Chemical and Physical Processes, Pisa, Italy
V. I. Roldughin, Frumkin Institute of Physical Chemistry and Electrochemistry, Russian Academy of Sciences, Moscow, Russia
V. A. Sadykov, Boreskov Institute of Catalysis, SB RAS, Novosibirsk, Russia
E. Scavetta, Università di Bologna, Bologna, Italy
R. Sennen Brusa, Dipartimento di Fisica, Università di Trento, Trento, Italy
H. Susanto, Lehrstuhl für Technische Chemie II, Universitlsquät Duisburg-Essen, Essen, Germany; and Department of Chemical Engineering, Universitas Diponegoro, Semarang, Indonesia
C. Téllez, Aragón Institute of Engineering Research, University of Zaragoza, Zaragoza, Spain
G. F. Tereshchenko, Topchiev Institute of Petrochemical Synthesis, Russian Academy of Sciences, Moscow, Russia
M. Tonelli, Università di Bologna, Bologna, Italy
J. Tong, Metallurgical and Materials Engineering, Colorado School of Mines, Golden, Colorado, USA
S. Tosti, ENEA, Dipartimento FPN, CR ENEA Frascati, Frascati (RM), Italy
M. Ulbricht, Lehrstuhl für Technische Chemie II, Universitlsquät Duisburg-Essen, Essen, Germany
T. Uragami, Faculty of Chemistry, Materials and Bioengineering Kansai University Suita, Osaka, Japan
A. Vaccari, Università di Bologna, Bologna, Italy
F. Varela-Gandía, Universidad de Alicante, Departamento de Química Inorgánica, Alicante, Spain
G. Vitulli, Advanced Catalysts Srl, Pisa, Italy
V. V. Volkov, Topchiev Institute of Petrochemical Synthesis, Russian Academy of Sciences, Moscow, Russia
Z. Wu, Department of Chemical Engineering, Imperial College London, London, UK
T. Yamaguchi, Chemical Resources Laboratory, Tokyo Institute of Technology, Yokohama, Japan
S. Yamaura, Institute for Materials Research, Tohoku University, Sendai, Japan
M. Yoshimune, Research Institute for Innovation in Sustainable Chemistry, National Institute of Advanced Industrial Science and Technology, Tsukuba, Japan
V. V. Zyryanov, Institute of Solid State Chemistry and Mechanochemistry, SB RAS, Novosibirsk, Russia
Glossary
Nomenclature
A
membrane area (m2)
b
Langmuir adsorption parameter (kPa−1)
bo
Langmuir pre-exponential parameter (kPa−1)
Biot number ()
dimensionless i component concentration
i component concentration ()
specific heat of the component i ( or )
gas mixture specific heat ()
Damköhler number
effective diffusivity in the solid particle ()
effective axial mass diffusivity ()
effective radial mass diffusivity ()
equivalent particle diameter (m)
internal tubular reactor diameter (m)
apparent activation energy ()
friction factor
Fsweep
sweeping gas flow rate ()
FTOT
inlet total gas mixture flow rate ()
G
Gibbs free energy ()
heat transport coefficient between gas and solid phase ()
i component enthalpy in permeation zone ()
i component enthalpy in reaction zone ()
heat of reaction, j ()
forced convection heat transport coefficient in the permeation zone ()
heat transport coefficient near the tube wall ()
wall heat transport coefficient for the fluid phase ()
wall heat transport coefficient for the solid phase ()
i component flux through the membrane ()
adsorption equilibrium constant of the component i (kPa−1)
rate constant of reaction j (depends on reaction)
equilibrium constant of reaction j
membrane thermal conductivity ()
tube wall conductivity ()
reactor length (m)
molecular weight of the component i ()
average molecular weight of the gas mixture ()
pressure (kPa)
dimensionless pressure in the reaction zone
pressure drop along the reactor (kPa)
inlet pressure (kPa)
permeability coefficient ()
permeability pre-exponential factor ()
axial Peclèt number
critical Peclèt number
radial mass Peclèt number ()
i component partial pressure (kPa)
i component partial pressure on the permeate (downstream) side (kPa)
i component partial pressure on the retentate (upstream) side (kPa)
i component partial pressure on the catalyst surface (kPa)
Prandtl number ()
Prandtl number in the permeation (downstream) zone
heat flux through the membrane ()
heat flux through the walls ()
radial coordinate (m)
radial dimensionless coordinate
universal gas constant ()
Reynolds number
Reynolds number referred to catalyst particle diameter ()
Reynolds number in the permeation (downstream) zone
reaction rate of component i in reaction j ( or )
Schmidt coefficient ()
ss
specific surface area of metal
Stanton number
steam to carbon ratio
temperature (K)
normal boiling temperature of component i (K)
inlet temperature (K)
membrane temperature (K)
wall temperature (K)
overall heat transport coefficient ()
gas superficial velocity ()
pellet volume (m3)
reactor volume (m3)
w
halfwidth of diffraction peaks
apparent residence time ()
i component conversion
molar fraction of component i
overall yield to species i
axial coordinate (m)
axial dimensionless coordinate
Greek Symbols
α
perm-selectivity
membrane thickness (m)
void fraction of packing
effectiveness factor
effectiveness factor of reaction j
θ
angular position of X-ray reflection
λ
wavelength (m)
effective thermal conductivity in the solid particle ()
effective axial thermal conductivity ()
effective radial thermal conductivity ()
gas phase thermal conductivity ()
thermal conductivity of the component i ()
thermal conductivity of packing material ()
radial coordinate inside the particle (m)
gas mixture viscosity ()
viscosity of the component i ()
catalytic bed density ()
gas density ()
ρm
weight concentration of metals in the solution (g l−1)
catalyst density ()
fugacity coefficient of species i in the gas mixture (kPa)
mean free path (m)
thermodynamic correction factor (−)
Subscripts or Superscripts
app
apparent
eff
effective parameter
g
gas translational
i
component in mixture
j
reaction number
s
surface
sat
saturation
SM
Stefan–Maxwell
Acronyms
AR
melamine-formaldehyde resin
CA
cellulose acetate
CM
catalytic membrane
CMC
catalytic membrane contactors
CMR
catalytic membrane reactor
DMF
N,N-dimethylformamide
DO
dissolved oxygen
EC
ethyl cellulose
MC-CN
deposition of Pd onto outer surface of membrane in continuous regimes
MC-CS
deposition of Pd onto outer surface of membrane in consecutive regimes
MR
membrane reactor
NMP
N-methyl-2-pyrrolidone
PAA
polyacrilic acid
PAI
poly(amide imide)
PAN
polyacrylonitrile
pCM
polymeric catalytic membrane
PDMS
poly(dimethylsiloxane)
PEBA
poly(ether-b-amide)
PEI
polyetherimide
PEMFC
polymer electrolyte membrane fuel cell
PES
polyether sulfone
PP
polypropylene
ppb
parts per billion
ppm
parts per million
PPO
poly(2,6-dimethyl-1,4phenylene oxide)
PSF
polysulfone
PVDF
polyvinylidene
PVP
poly(vinylpyrrolidone)
THF
tetrahydrofurane
TR
traditional reactor (reactor without membranes)
WHSV
weight hourly space velocity
Introduction – A Review of Membrane Reactors
Fausto Gallucci1, Angelo Basile2, Faisal Ibney Hai3
1Chemical Process Intensification, Faculty of Chemical Engineering and Chemistry, Eindhoven University of Technology, Eindhoven, The Netherlands 2Institute on Membrane Technology, CNR, c/o University of Calabria, Rende, CS, Italy 3Environmental Engineering, The University of Wollongong, New South Wales, Australia
1 Introduction
In recent decades, membrane catalysis has been studied by several research groups, and significant progress in this field is summarised in several review articles [7, 143, 146, 154, 194, 195, 202].
Considering a IUPAC definition [131], a membrane reactor (MR) is a device for simultaneously performing a reaction (steam reforming, dry reforming, autothermal reforming, etc.) and a membrane-based separation in the same physical device. Therefore, the membrane not only plays the role of a separator, but also takes place in the reaction itself. The term membrane bioreactor (MBR), however, refers to the coupling of biological treatment with membrane separation in contrast to the sequential application of membrane separation downstream of classical biotreatment [117, 237]. This introduction comprises a review of both MR (Sections 2–5) and MBR (Section 6).
2 Membranes for Membrane Reactors
The membranes can be classified according to their nature, geometry and separation regime. In particular, they can be classified into organic, inorganic and organic/inorganic hybrids.
The choice of membrane type to be used in MRs depends on parameters such as the productivity, separation selectivity, membrane life time, mechanical and chemical integrity at the operating conditions and, particularly, the cost.
The discovery of new membrane materials was the key factor for increasing the application of the membrane in the catalysis field. The significant progress in this area is reflected in an increasing number of scientific publications, which have grown exponentially over the past few years, as shown by McLeary . [154].
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