Fm Velterop

Industrial objective is to offer ZEOMEM (monocrystalline defect free zeolite molecular sieve with pores between 3-5A) membrane processes to a range of markets: oleochemical, agrochemical, fine petrochemical and environmental purification of air or other gasses. The core group proposers (system integrators or system integrators / end- users Setec-NL, K.D. Pharm a-DE, Vioryl-GR, Atlantis-GR and Biodesign-UK) aim to offer the superior characteristics of ZEOMEM processes to end-users in these sectors. The interest from industry in this technology is such that ZEOMEM is expected to result in sharp increases of turnover for the core group proposers if the project is successful. Technical objective is 1st to develop the labscale technology of defect-free zeolite membranes on robust substrates together with sealing, module and production technologies into a process that is fit for batch production of ZEOMEM modules. The 2nd technical objective is techno-economically feasible installations / process routes that can be proven to operate much more efficiently with less environmental impact under less demanding working conditions. The large potential end-users in the consortium aim to achieve to gain insight and experience on the requirements and benefits of applications of the membrane which can lead to further development for larger scale processes. The work is structured as a parallel development of membrane module and process modelling tools and process models for potential applications. Four example processes have been identified by potential end-users: toluene removal from air, dehydration of esterification reaction mixture at 260øC, dehydration of a caprolactam byproduct at 280øC and dehydration of various reaction mixtures in a multipurpose reaction vessel at 80 -130øC. Each sector is represented by a potential end-user: Atlantis-GR, Unichema-NL, DSM-NL, SKW-DE and Purac Biochem-NL. RTD performers are Smart Chemical Company (membrane process development),Velterop (module design and sealings), ATO-DLO (process analysis and modelling, characterisation of membrane, labscale testing) and Viana (characterisation of air purification and development of feasible filter set-up). The membrane work is developing a process that can be industriali'd to bond the zeolite membrane on a commercially available support, defect free and robust enough to withstand aggressive environments (pH <1, >12) and high temperatures (>300øC). Module development focusses on high temperature, high pressure resistant seals and joints to avoid thermoshock cracking and allow for economical production of a module with optimal performance. The process model development focusses on creating the right tools for specific modelling with this new membrane unit and optimizing process parameters in order to use the membrane as efficiendy as possible while minimizing any changes to the presently used process installation. The work is executed by a mix of companies and institutes that aim to exploit the potential offered by 'olite membrane - robust support technology. Main deliverables of dhe project are: 8 monotubular modules with specific process labtest results under real life conditions; modelling tools for ZEOMEM process development and assessment; database with membrane performance test results; overall techno-economical assessment of example processes. These results are to be developed by some of the partners in order to be commercialized in the various application sectors. The large scale application opportunities are to be developed in cooperation with partner Royal Schelde which has the appropriate resources and market presence to execute market development in these areas. The actual production of the ZEOMEM membrane modules is to be undertaken by a virtual industry cluster consisting of the core group proposers together with Smart Chemical Company, Velterop and Royal Schelde.

Zeolite membranes on ceramic or sintered steel substrates allow for high-temperature pervaporation and other separation processes with a performance which cannot be achieved with other membranes. Application of these membranes will result in lower energy consumption (up to 60%!), less pollution, more efficiency and a purer product. Relevant processes are found on a very large scale in petrochemical industry, but on a small and medium scale also in agro chemical, pharmaceutical and chemical specialities processes. The project aims to develop a zeolite membrane in tubular form which is defect free and can be used in >200°C environments of aggressive solvents such as esters or acetone. Parallel development will be focused on the smaller and medium sized processes in which the zeolite membrane will be used. Based on the results of the project, project partners can develop (applications for) a commercial zeolite membrane module of 0.8m2. Velterop BV has developed and applied patents for the sealing and joining technology to incorporate high-temperature membranes in chemical process modules, and Smart Chemical Company Ltd has applied 3 patents for technology to adhere zeolite membrane directly on a large pore substrate without additional bonding material. Technical work will involve the development of the technology into a industrially feasible process for small and medium quantities of tubular membranes, and the development of commercially feasible processes with these zeolite membranes. At least 4 end-users will be involved to focus the development on the applications. Anticipated additional turnover for each of the proposers is several millions of ECU to be reached within 5 years after completion of the project. Both SMEs intend to licence the resulting technology to larger industrial-process- contractors/engineers in order to cover larger-scale markets. The economic impact at the endusers' side would involve up to 25% savings in process costs. Safety and environmental impact is also very positive as energy consuming, less efficient or waste producing processes such as distillation, adsorption or polymer membrane separation can be avoided. The envisioned project would have a budget of + .0 million ECU and last for 3 years. Several companies and institutes have indicated interest and have indicated that the time to market for the development after completion of the project would be Limited to 2 3 years for the small and medium sized applications.