SGER: Precision Fabrication of Multi-Component, Multi-Functional Catalytic Membranes Using Photolithography

智力优点：膜反应器将反应和分离结合在同一装置中，并通过在形成产物时去除产物来改变平衡并提高产率。 选择性透氧膜可用作选择性催化反应器，例如用于商业化生产合成气。 该项目负责人计划使用光刻技术来制造多功能催化膜，该膜由在功能性选择性透氧膜上组装的催化剂簇组成。 光刻技术的使用应该会产生高度可重复的制造工艺，从而减少当前催化制造技术中固有的批次内和批次间的变异性。 该制造工艺将通过类似于半导体行业中采用的晶圆制造技术的自动化制造工艺来降低膜制造成本。 对通过膜的氧通量的增强效应将为选择性透氧膜在工业上变得有吸引力提供必要的技术。 该技术还可以通过制造多组分、多功能多相催化剂来影响模型催化剂的研究，这些催化剂可以进行测试和表征，以获得有关每种催化剂组分功能的基本信息。 此外，该项目的成功完成应该会产生一种可以在实验室规模上进行研究和建模的膜反应器，然后通过制造更大的膜晶片或并联反应器堆来扩大规模。将获得有关处理过程中簇尺寸、均匀性和膜稳定性的基本信息，以及对反应机理、每个组分的作用以及催化剂对通过膜的氧传输的直接影响的理解。 将使用场发射扫描电子显微镜和能量色散 X 射线分析对膜进行表征。 氧气渗透性和膜的稳定性将通过在线气相色谱仪和质谱仪监测的甲烷部分氧化进行测试。广泛影响：使用选择性透氧膜可实现的潜在进步可能使其成为燃料电池制氢（能源和环境影响）、氧气传感器（国土安全）、从氧气流中过滤有害成分（国土安全）和制氧系统等应用的可行技术。

Intellectual Merit:Membrane reactors combine reaction and separation in the same unit and shift the equilibrium and increase yield by removing a product as it is formed. Selective oxygen permeable membranes may be used as selective catalytic reactors for example to make syngas commercially. The PI plans to use photolithographic techniques to fabricate multi-functional catalytic membranes consisting of assembled catalyst clusters on a functioning selective oxygen permeable membrane. The use of photolithography should result in a highly reproducible fabrication process that will reduce the intra-batch and inter-batch variability that is inherent in current catalytic manufacturing techniques. The fabrication process will reduce membrane fabrication cost by producing an automated manufacturing process similar to the wafer fabrication technology employed in the semiconductor industry. The enhancement effects on the oxygen flux through the membrane will provide the technology necessary for selective oxygen permeable membranes to become industrially attractive. The technique could also influence the study of model catalysts by fabricating multi-component, multi-functional heterogeneous catalysts that can be tested and characterized to gain fundamental information about the functionality of each catalyst component. In addition, the successful completion of the project should result in a membrane reactor that can be studied and modeled at bench scale and then scaled-up by making larger membrane wafers or stacks of parallel reactors.Fundamental information about cluster size, uniformity, and membrane stability during processing will be obtained, as well as an understanding of the reaction mechanism, the role of each component, and the direct effect of the catalyst on the oxygen transport through the membrane. The membranes will be characterized using Field Emission Scanning Electron Microscopy and Energy Dispersive X-Ray Analysis. The oxygen permeation and the stability of the membranes will be tested using the partial oxidation of methane monitored with an online gas chromatograph and mass spectrometer.Broad Impact:The potential advances achievable using selective oxygen permeable membranes could make them a viable technology for applications such as hydrogen production for fuel cells (energy and environmental impact), oxygen sensors (homeland security), filtration of hazardous components from an oxygen stream (homeland security), and oxygen generation systems.