The
reproducible fabrication of large-area zeolite membranes for
gas separation is still a great challenge. We report the scalable
fabrication of high-performance zeolite MFI membranes by single-step
secondary growth on the 19-channel alumina monoliths for the first
time. The packing density and mechanical strength of the monolithic
membranes are much higher for these than for tubular ones. Separation
performance of the monolithic membranes toward the butane isomer mixture
was comparably evaluated using the vacuum and Wicke–Kallenbach
modes. The n-butane permeances and n-butane/i-butane separation factors for the three
membranes with an effective area of ∼84 cm2 were
>1.0 × 10–7 mol (m2 s Pa)−1 and >50 at 343 K for an equimolar n-butane/i-butane mixture, respectively. We succeeded
in scaling
up the membrane synthesis with the largest area of 270 cm2 to date which has 1.3 times the area of an industrial 1 m long tubular
membrane. Monolith supported zeolite MFI membranes show great potential
for industrial n-butane/i-butane
separation.