Periodic Reporting for period 1 - MEASURED (MEMBRANE SCALE UP FOR CHEMICAL INDUSTRIES)
Berichtszeitraum: 2023-01-01 bis 2024-06-30
In MEASURED, 3 membrane processes have been identified that can be scaled-up to TRL7 and make a difference in the chemical industry: (i) pervaporation (PV); (ii) gas separation (GS) and (iii) membrane distillation (MD). MEASURED specific objectives are:
- To develop at TRL7 three new generation membrane materials (ceramic, organic, carbon-based) for three different applications (pervaporation, membrane distillation, gas separation, respectively)
- To scale-up the synthesis process for the manufacture of the above mentioned membranes
- To evaluate cross-fertilization possibilities of the different membranes between the different cases of the project.
- to model at multiscale level the different membranes to guide the development activities and identify a TRL9 roadmap
- To develop three prototypes for the three technologies and test them at TRL7
- To develop a full LCA, LCC and Health and Safety Analysis (HSE) of MEASURED
- To pave the way for future exploitation of MEASURED Key Exploitable Results (KER) - To elaborate the business cases for the three technology lines
- To promote the dissemination and communication of MEASURED’s results and expand its impact
- To develop at TRL7 three new generation membrane materials (ceramic, organic, carbon-based) for three different applications (pervaporation, membrane distillation, gas separation, respectively)
- To scale-up the synthesis process for the manufacture of the above mentioned membranes
- To evaluate cross-fertilization possibilities of the different membranes between the different cases of the project.
- to model at multiscale level the different membranes to guide the development activities and identify a TRL9 roadmap
- To develop three prototypes for the three technologies and test them at TRL7
- To develop a full LCA, LCC and Health and Safety Analysis (HSE) of MEASURED
- To pave the way for future exploitation of MEASURED Key Exploitable Results (KER) - To elaborate the business cases for the three technology lines
- To promote the dissemination and communication of MEASURED’s results and expand its impact
WP1 Exploitation and business plan: Market and Stakeholder Analysis has been carried out based on the markets of the identified KERs in the three business cases (gas separation, pervaporation and membrane distillation). A mixed approach consisting of data-driven analysis and interviews with project external and internal players has been used. 12 KERs were identified.
WP2 Coordination: Overall administrative and contractual management of the period has been carried out including e.g. data management plan, templates, timely submission of official reporting. Project Technical Committee and General Assembly meetings took place regularly. Internal communication tool (Teams group) has been established and regular updates performed.
WP3 Membrane evaluation and scale-up:
- Development and characterization of membranes prepared using a bio-based solvent and of specific coatings to enhance their performance in MD. Hybrid organic/inorganic coatings were deposited by dip coating with and without hydrophilic pore-former. A flux of 8 kg/m2h in was obtained with the supported and coated PGVL membrane.
- Innovative carbon molecular sieve membranes were used to sieve away the H2 and the CO2, purifying methane. Between M1 and M18, these membrane sieves were prepared by coating a plastic precursor onto suitable ceramic supports, and carbonizing it at high temperature. One particular preparation method led to a well-performing membrane, whose formulation could be used for the preparation of the membrane separator prototype.
- Pervaporation technology is applied to esterification reaction by removing water. Over the first 18 months, two generations of Hybrid Silica (HybSi) membranes were developed and tested. Stable performance was achieved over 2 months operation. Membranes are now being scaled up for pilot plant trials at Arkema.
WP4 Engineering and construction: Conceptual and basic engineering was carried out for each technology line with the overarching goal of design, construct and develop the three different prototypes that will be used in the demonstration phase for PV, MD and GS. This encompassed, among other things: Process Flow Diagram, Process & Instrumentation Diagram, initial equipment sizing, preliminary HAZID and risks assessment, including alarm lists and safety procedures.
WP5 Technology evaluation: The prototype for each technology (PV, MD and GS) will be demonstrated in a dedicated operational environment (Arkema, GVS and Gaya plant, respectively) and for its specific application (acrylic ester production, membrane manufacturing and methanation, respectively). Here the work during M1-M18 has focused on interface definition between the prototypes and the demonstration sites, including HAZOP studies, list of connections, energy supply needs.
WP6 Modelling: In the first 18 months of the project, two parallel activities have been ongoing: multi-scale membrane modelling and environmental assessments. Detailed multi-scale modelling is investigating the permeation mechanisms and modules performance. CFD calculations have been performed to assess the entity of relevant losses (i.e. concentration and temperature polarization), to be able to later include them in a mathematical description of the module. On the other side, in the life-cycle environmental perspective the methodology has been defined to assess the impact of the innovative membrane-based solutions proposed in this project: environmental impact through LCA; social impact based on critical material usage through social-LCA; circularity assessment based on material recirculation.
WP7 Dissemination and education: The project results, goals and expected impacts are disseminated and communicated to identified target groups, stakeholders and public audience, through participation to strategic events, website regular updates, Social media posts (LinkedIn, Twitter), press releases, newsletters, project video, promotional material (leaflet, poster and roll-up, public project presentation).
WP2 Coordination: Overall administrative and contractual management of the period has been carried out including e.g. data management plan, templates, timely submission of official reporting. Project Technical Committee and General Assembly meetings took place regularly. Internal communication tool (Teams group) has been established and regular updates performed.
WP3 Membrane evaluation and scale-up:
- Development and characterization of membranes prepared using a bio-based solvent and of specific coatings to enhance their performance in MD. Hybrid organic/inorganic coatings were deposited by dip coating with and without hydrophilic pore-former. A flux of 8 kg/m2h in was obtained with the supported and coated PGVL membrane.
- Innovative carbon molecular sieve membranes were used to sieve away the H2 and the CO2, purifying methane. Between M1 and M18, these membrane sieves were prepared by coating a plastic precursor onto suitable ceramic supports, and carbonizing it at high temperature. One particular preparation method led to a well-performing membrane, whose formulation could be used for the preparation of the membrane separator prototype.
- Pervaporation technology is applied to esterification reaction by removing water. Over the first 18 months, two generations of Hybrid Silica (HybSi) membranes were developed and tested. Stable performance was achieved over 2 months operation. Membranes are now being scaled up for pilot plant trials at Arkema.
WP4 Engineering and construction: Conceptual and basic engineering was carried out for each technology line with the overarching goal of design, construct and develop the three different prototypes that will be used in the demonstration phase for PV, MD and GS. This encompassed, among other things: Process Flow Diagram, Process & Instrumentation Diagram, initial equipment sizing, preliminary HAZID and risks assessment, including alarm lists and safety procedures.
WP5 Technology evaluation: The prototype for each technology (PV, MD and GS) will be demonstrated in a dedicated operational environment (Arkema, GVS and Gaya plant, respectively) and for its specific application (acrylic ester production, membrane manufacturing and methanation, respectively). Here the work during M1-M18 has focused on interface definition between the prototypes and the demonstration sites, including HAZOP studies, list of connections, energy supply needs.
WP6 Modelling: In the first 18 months of the project, two parallel activities have been ongoing: multi-scale membrane modelling and environmental assessments. Detailed multi-scale modelling is investigating the permeation mechanisms and modules performance. CFD calculations have been performed to assess the entity of relevant losses (i.e. concentration and temperature polarization), to be able to later include them in a mathematical description of the module. On the other side, in the life-cycle environmental perspective the methodology has been defined to assess the impact of the innovative membrane-based solutions proposed in this project: environmental impact through LCA; social impact based on critical material usage through social-LCA; circularity assessment based on material recirculation.
WP7 Dissemination and education: The project results, goals and expected impacts are disseminated and communicated to identified target groups, stakeholders and public audience, through participation to strategic events, website regular updates, Social media posts (LinkedIn, Twitter), press releases, newsletters, project video, promotional material (leaflet, poster and roll-up, public project presentation).
MEASURED aims to increase the R&I maturity of the targeted membrane technologies (pervaporation, membrane distillation, and gas separation) with applications to acrylic ester production, waste water and waste gas produced in industrial processes, from current TRL 4-5 to TRL7. Expected results are:
- Pervaporation: Advanced hybrid silica membranes with improved H2O flux and surface area, stability, resistance to acid environment, efficient cleaning in place strategies, reduced costs. Final demonstration of 1 m2 of membrane in an industrial setting (ARKEMA industrial production of acrylic ester).
- Membrane distillation: Substitution of conventional toxic aprotic polar solvents with green ones with increased recovery factor of water/alcohol mixture, improved volumetric reduction factor and rejection of HBPS, stability against fouling (flux reduction < 10%); Membranes will be used to purify the wastewater stream coming from the manufacturing facility of PVDF membranes at GVS Spa (Bologna, Italy) treating 70 L/h, while renewable energy is supplied during the demonstration campaign.
- Gas separation: Supported Carbon Molecular Sieve Membranes with ideal selectivity H2/CH4 > 400 at room temperature; - Up-scale the production to multi-tubular membranes, optimized sealing technology. The membranes will be tested at ENGIE (GAYA plant) for separation of H2 from methanation off-gas for reaching the gas grid grade. The membrane area that will be installed in the Demo plant will be 1.2 m2;
- Pervaporation: Advanced hybrid silica membranes with improved H2O flux and surface area, stability, resistance to acid environment, efficient cleaning in place strategies, reduced costs. Final demonstration of 1 m2 of membrane in an industrial setting (ARKEMA industrial production of acrylic ester).
- Membrane distillation: Substitution of conventional toxic aprotic polar solvents with green ones with increased recovery factor of water/alcohol mixture, improved volumetric reduction factor and rejection of HBPS, stability against fouling (flux reduction < 10%); Membranes will be used to purify the wastewater stream coming from the manufacturing facility of PVDF membranes at GVS Spa (Bologna, Italy) treating 70 L/h, while renewable energy is supplied during the demonstration campaign.
- Gas separation: Supported Carbon Molecular Sieve Membranes with ideal selectivity H2/CH4 > 400 at room temperature; - Up-scale the production to multi-tubular membranes, optimized sealing technology. The membranes will be tested at ENGIE (GAYA plant) for separation of H2 from methanation off-gas for reaching the gas grid grade. The membrane area that will be installed in the Demo plant will be 1.2 m2;