COMPOSITE MEMBRANE

Abstract: A composite membrane excellent in the resistance to organic solvent, heat and organic vapor and usable for pervaporation, gas separation and reverse osmosis, which is composed of a porous membrane mainly comprising a polymer having repeating units of formula (I) and an active layer formed thereon: -( Ph - S - Ph SO₂ -) n (I) wherein Ph represents phenyl and n is a natural number.

Description: The present invention relates to a composite membrane capable of selective separation of liquid mixtures, especially for the separation of aqueous solutions containing organic solvents or aqueous solutions at high temperatures and to a composite membrane capable of selective separation of mixed gases, which has high gas permeability, high separation ability and high resistance to organic vapors. As a separation membrane for the selective separation of liquid mixtures by reverse osmosis, asymmetric cellulose acetate membrane is used industrially. However, this asymmetric membrane has poor resistance to attack by, for example, hydrolysis, microorganisms, chemicals and also has poor heat resistance. Thus, although the membrane is practically used in some areas of technology, it does not have a wide applicability. Active investigations for new materials which eliminate these drawbacks of cellulose acetate membranes are now being carried out, mainly in the USA and Japan. Such newly proposed materials include aromatic polyamides, polyamide hydrazides (US-A-3567632), polyamide acids (JP-A-55-37282), cross-linked polyamide (JP-B-56-3769), polyimidazopyrrolones, polysulfoneamides, polybenzimidazoles, polybenzimidazolones and polyaryleneoxides. However, although some materials which overcome some of the drawbacks of cellulose acetate membrane have been obtained, they are inferior to the cellulose acetate membrane in their selective separation ability and permeability. Another such newly proposed membrane for reverse osmosis is disclosed in EP-A-0417287, acknowledged under Art 54(3) EPC. This discloses an asymmetric membrane of a phenylene sulfide sulfone polymer of the formula (PhS) m (PhX) n , in which Ph is a phenylene group, X is SO 2 or CO 2 and m and n are each a whole number, which polymer is optionally oxidized. A dense surface portion of the membrane serves as the active layer, or alternatively the membrane serves as a support of a composite reverse osmosis membrane or a support of a gas separation membrane. On the other hand, composite membranes having a porous support membrane coated with a separate active layer controlling the membrane performance have been developed. In the composite membranes, the best material for each of the active layer and for the porous support can be independently selected, so that freedom of membrane formation is greater. Furthermore, unlike the asymmetric membranes which need to be stored in a wetted condition, the composite membranes can be stored in dry state. Examples of such composite membranes are described in JP-A-49-133282, JP-B-55-38164, PB Report 80-182090, JP-B-59-27202, JP-A-56-40403, US-A-3744642, US-A-3926798, JP-A-58-24303, JP-A-61-42302 and EP-A-0015149, corresponding to US-A-4277344 and JP-A-55-147106. Among these composite membranes, those having a polysulfone porous membrane and a cross-linked polyamide active layer formed on the porous membrane constitute the main stream of the composite membranes, and these are attracting attention as reverse osmosis membranes with high permeability and high selective separation ability. However, since the polysulfone support membrane employed as the porous membrane has poor heat resistance and solvent resistance, the selective separation performance is impaired if the membrane is used for the separation of an aqueous solution containing an organic solvent or for the separation of aqueous solutions at a high temperature. There are a number of properties which a practical reverse osmosis membrane should have, such as high permeability and high selective separation ability, as well as high heat resistance and high chemical resistance. However, no membranes have been provided which simultaneously satisfy the high heat resistance and high chemical resistance. Thus, although there are membranes which can exhibit their separation ability for the separation of aqueous solutions containing organic solvents in low concentrations, if these membranes are used for the separation of an aqueous solution containing an organic solvent at a high concentration, the membrane itself or the support membrane becomes swollen or is dissolved by the organic solvent so that the separation performance is impaired. Thus, the use of such composite membranes is limited. Reference is now made to membranes capable of use for the selective separation of gas mixtures. It is necessary that such membranes have a high gas permeability and high separation ability. To attain this, it is necessary that the membrane be in composite form having an active layer formed on a porous membrane of, for example, cellulose acetate, polyphenylenesulfone or polyphenylene sulfide (JP-A-61-432). In particular, JP-A-59-120207 discloses composite membranes having an active layer made of a silicone-based material and a porous substrate membrane made of polysulfone, polyether sulfone or cellulose acetate. However, the resistance of such conventional composite membranes to organic vapor is low, so that if the gas mixture to be separated contains vapor of a polar solvent such as toluene vapor or trichloroethylene vapor, the composite membrane is broken. Membranes for a wide range of applications, including reverse osmosis and gas separation, are also disclosed in EP-A-0422251, acknowledged under Art 54(3) EPC. The membranes have an appropriate active layer deposited on a polysulfone substrate formed by oxidation of a polymer of the general formula wherein each of R 1 and R 2 is a phenylene or diphenylene group, k is 0 or 1-10 and 1 is 0 or 1. The present invention seeks to provide a composite membrane with high solvent resistance, heat resistance and high resistance to organic vapor, which exhibits good separation performance. More particularly, the present invention seeks to provide a reverse osmosis membrane which exhibits high selective separation ability and high water permeability, which has a high heat resistance and solvent resistance. After intensive investigations, we found that a composite membrane comprising a porous membrane made of a specific copolymer containing phenylenesulfide units and an active layer formed on the porous membrane exhibits high selective separation ability and has high permeability and excellent solvent resistance. Thus, the present invention provides a composite membrane comprising (1) a porous membrane of a polymeric material consisting essentially of a polymer having phenylenesulfide-phenylenesulfone repeating units adjacent to one another, which polymer has n said repeating units and which said repeating unit is represented by the formula (I) (Ph-S-Ph-SO 2 ) wherein Ph represents a phenyl group and n represents a whole number and, deposited on the porous membrane (1), (2) an active layer of a material selected from cross-linked polyamides prepared by interfacial polycondensation. The invention also provides the use of such a composite membrane for reverse osmosis and a method of preparing such a composite membrane which method comprises the steps of forming a porous membrane of a polymeric material consisting essentially of a polymer having phenylenesulfide-phenylenesulfone repeating units adjacent to one another, which polymer has n said repeating units and which said repeating unit is represented by the formula (I) (Ph-S-Ph-SO 2 ) (wherein Ph represents a phenyl group and n represents a whole number), optionally oxidising the polyphenylene sulfone sulfide polymer of the porous membrane and, either prior or subsequently to any such oxidation, depositing on the porous membrane an active layer of a material selected from cross-linked polyamides prepared by interfacial polycondensation. By the present invention, a composite membrane with high solvent resistance, heat resistance and high resistance to organic vapor, which exhibits good separation performance is provided. More particularly, by the present invention, a reverse osmosis membrane which exhibits high selective separation ability and high water permeability, which has a high heat resistance and solvent resistance is provided. Composite membranes embodying the present invention can be used for the treatment of waste liquids in the food industry, polymer industry and petroleum chemical industry, to which the conventional composite membrane cannot be applied. Thus, the composite membrane of the present invention will greatly contribute to separation processes utilizing membranes. The most preferred methods for carrying out the invention will now be described. In the composite membrane of the present invention, the porous membrane is a layer which does not itself have a substantial separation ability, but which is for reinforcing the active layer having the separation ability. The porous membrane may have uniform fine pores or may have fine pores the diameters of which gradually increase from one side of the membrane to the other, the pore diameters at the side with smaller diameters being preferably not more than 100 nm. In the present invention, the porous membrane consists essentially of the polyphenylenesulfide sulfone of the formula (I) described above, which is excellent in heat resistance and solvent resistance. In the above-described formula (I), n represents a whole number. Although the number is not restricted, if the molecular weight is too large, it is difficult to dissolve the polymer in a solvent. On the other hand, if the molecular weight is too small, the mechanical strength of the membrane is low. Thus, the molecular weight of the polyphenylenesulfide sulfone is preferably several tens thousand to about 100,000. Although the porous membrane in the present invention may preferably be made of the polyphenylenesulfide sulfone represented by the formula (I) alone, as long as the properties of the membrane are not adversely affected, a unit other than the above-described phenylenesulfide sulfone unit may be contained in the polymer or a polymer other than the above-mentioned polyphenylenesulfide sulfone may be blended in the polymer. The porous membrane employed in the present invention may be in any form such as a flat membrane, hollow fibers or a tube. The flat membrane may be used in the form of a spiral type, plate type or frame type membrane, and the tubes and the hollow fibers may be used in bundled form so as to constitute an element. The thickness of the flat porous membrane may preferably be 10 µm to 300 µm in view of the pressure resistance, and more preferably 30 µm to 100 µm having regard to liquid permeation resistance. In cases where the porous membrane is in the form of a flat membrane, the membrane may be laminated on a fabric or a non-woven fabric so that the membrane is reinforced. In this case, the fabric or the non-woven fabric may preferably be made from a polymer such as polyester, polyamide, polyethylene, polypropylene or polyphenylenesulfide. The polyphenylenesulfide sulfone polymer represented by the formula (I) may be prepared by a known process as described in, for example, JP-A-63-270736, corresponding to EP 0 280 325 A. That is, the polyphenylenesulfide sulfone may be prepared by polymerizing bis(4-chlorophenyl)sulfone and sodium hydrogen sulfide in N-methylpyrrolidone solvent under heat. The porous membrane employed in the present invention may be prepared by dissolving the above-described phenylenesulfide sulfone polymer in a solvent, pouring the solution into a mold, and casting the molded solution into a non-solvent of the polyphenylenesulfide sulfone to coagulate the molded solution, which non-solvent is miscible with the solvent in which the polyphenylenesulfide sulfone is dissolved. It should be noted, however, the process of producing the porous membrane is not restricted to the wet process since a process of making the polymer porous after melt-molding of the polymer or a process in which the porous membrane is molded from dispersed polymer may also be employed. Preferred solvents for dissolving the polymer include aprotic solvents, acids and phenol compounds, although the solvents are not restricted thereto. Examples of the preferred solvents include dimethylsulfoxide (DMSO), N-methylpyrrolidone (NMP), N,N-dimethyl-2-imidazolidinone (DMI), hexamethylphosphoric triamide (HMPA), sulfuric acid, dichloroacetic acid, p-chlorophenol and m-cresol since these solvents well dissolve the polymer. As a characteristic common to these solvents, the solubility parameters (δ) of these solvents are about 11. The δh more largely contributes to the solubility of the copolymer than δd and δp (wherein δh, δd and δp represent hydrogen bond force, dispersion force and polarity force components, respectively). In addition to the above-described solvents, for example, ε-caprolactam, γ-butyrolactone, sulfolane, diphenylsulfide, diphenylamine, δ-valerolactam, dimethylformamide (DMF) and tetramethylurea may be employed. The solvent may also be a mixed solvent. That is, a mixture of two or more of the above-described solvents or a mixture of the above-described solvent and a solvent other than mentioned above may be employed. For example, in the case where NMP is used as the solvent, not only the aprotic polar solvents but also halogenated hydrocarbons, ketones, organic acids and amino compounds may be added to the solvent. By the addition of these solvents, the solubility of the polymer may be promoted and the change in the structure of the membrane or the separation efficiency due to a change in the g value (coagulation value) may be controlled. To control the pore size of the membrane, an inorganic salt, acid, non-solvent of the copolymer and/or a macromolecular compound may be added to the phenylenesulfide-based polymer solution. As the inorganic salt, those which are well dissolved in the aprotic solvent are preferred, of which examples include sodium chloride, sodium bromide, lithium chloride, sodium iodide, potassium thiocyanate, potassium iodide, potassium chloride, iodine, lead acetate, lead chloride, lead nitrite and potassium permanganate. Preferred examples of the acid include acetic acid, trimellitic acid, lactic acid, propionic acid, valeric acid, citric acid, benzoic acid, sulfuric acid and dichloroacetic acid. Preferred examples of the macromolecular compound include polyvinyl alcohol, polyethylene glycol and polyvinylpyrrolidone. The amount of these additives may usually be, although not restricted to, 0.1 - 40% by weight. As the amount of these additives is increased, the pore size of the membrane is enlarged. The dissolving of the polymer is usually carried out at a temperature not higher than the boiling point of the solvent. In cases where the solubility of the polymer is extremely low, a pressure may be applied to the solvent so as to elevate its boiling point, and the polymer may be dissolved in the solvent under a temperature not higher than the elevated boiling point. To remove contaminants, it is preferred to filter the polymer solution obtained. Although it is preferred to conduct the filtration using a membrane filter, in cases where the viscosity of the solution is high, a cotton filter may be employed, or the filtration may be carried out at a high temperature. The resulting filtrate is hereinafter referred to as a "casting solution". Although the concentration of the casting solution may be selected arbitrarily within the range of the solubility of the copolymer in the solvent, if the concentration is too low, the formed membrane structure is weak, and if the concentration is too high, the membrane is difficult to permeate. In general, if the concentration is high, a membrane with high solute rejection and low permeation is obtained. Usually, the concentration of the polymer in the casting solution may preferably be 10 - 30% by weight. In the case of flat membranes, a concentration of 15-25% by weight is preferred, this giving an appropriate viscosity for obtaining practical membrane properties. Since the hollow fiber is not supported by a substrate, the concentration of the casting solution may preferably be higher than that employed in the preparation of flat membranes. That is, 18 - 30% by weight is usually preferred. Having regard to retention of the shape of the hollow fiber during the spinning step and to the separation performance, a viscosity of not less than 0.5 poise is preferred. When preparing a flat membrane, the casting solution is cast on a substrate to a prescribed thickness. When preparing a hollow fiber, the casting solution is extruded from a double spinneret and the spun fiber is introduced into a non-solvent of the polymer, which is miscible with the solvent of the casting solution. When preparing a flat membrane, the thickness of the casting solution may preferably be, although not restricted to, 30 - 600 µm because good membrane performance may be obtained. A hollow fiber may be prepared by extruding the polymer solution from the outer spinneret of a double spinneret while providing a jet of a gas or a liquid from the inner spinneret so as to form a hollow fiber structure, and introducing the fiber thus obtained into a coagulating liquid. The separation performance of the membrane may be controlled by controlling the temperature in the spinneret, the temperature of the coagulating liquid, the composition of the liquid or gas in the jet, the time from extrusion to coagulation and/or the draft value. The temperature of the casting solution, the time from the casting to the coagulation, the temperature and humidity of the environment from the casting to the coagulation, and the temperature of the coagulating liquid influence the separation performance of the membrane. In many cases, if the temperatures are low, membranes with high solute rejections and low permeabilities are obtained. The coagulation liquid is a liquid which is freely miscible with the solvent of the casting solution and a non-solvent of the polymer, and may be a single substance or a mixture of liquids. To control the coagulation speed of the casting solution, an inorganic salt and/or an organic compound may be added to the casting solution. Preferred examples of the inorganic salt may include sodium chloride, sodium bromide, lithium chloride, sodium iodide, potassium thiocyanate, potassium iodide, potassium chloride, iodine, lead acetate, lead chloride, lead nitrite and potassium permanganate. Preferred examples of the organic compound may include methanol, ethanol, isopropanol, butanol, polyethylene glycol, polyvinylpyrrolidone, polyvinyl alcohol, N-methylpyrrolidone, N,N-dimethylimidazolidone, dimethylformamide, dimethylsulfoxide and hexamethylphosphoric triamide. In cases where it is desired to slow down the coagulation speed, a good solvent of the copolymer may be added to the coagulation liquid. The concentration of these additives is not restricted and is usually 1 - 30% by weight. In cases where an aprotic polar solvent and an acid are used as the casting solution, the coagulation liquid may preferably be selected from, although not restricted to, water, methanol, ethanol, isopropanol and butanol. The temperature of the coagulation liquid is an important factor, as is the composition of the coagulation liquid, for controlling the separation performance of the membrane. Usually, the temperature of the coagulation liquid may preferably be 0 - 50°C. By oxidizing the thus obtained porous membrane so as to convert a part of the sulfide bonds into sulfone bonds, the heat resistance, chemical resistance and hydrophilicity of the membrane are further promoted. The oxidation may be carried out using an oxidizing agent. Preferred examples of the oxidizing agent include, although not restricted to, hydrogen peroxide, organic peroxides (e.g., peracetic acid, perbutyric acid, perbenzoic acid and chloroperbenzoic acid), alkali metals, alkaline earth metals, quaternary ammonium hypochlorite, chlorine, chromic acid, alkali metal permanganates and nitric acid. Since the oxidation reaction is a solid-liquid heterogeneous reaction, the oxidizing agent per se and/or the solvent thereof may preferably be one which can swell the polymer without changing the microstructure of the membrane so much. From this viewpoint, organic peroxides and/or quaternary ammonium hypochlorite dissolved in an organic solvent are especially preferred. In particular, peracetic acid, chloroperbenzoic acid and tetrabutylammonium hypochlorite solution in ethyl acetate are especially preferred for efficiently promoting the durability of the polymer. The oxidation may be carried out by immersing the porous membrane in a solution of the oxidizing agent. Although the temperature of the solution of the oxidizing agent is not restricted, usually 0 - 50°C is preferred. To carry out the reaction efficiently, the reaction may be conducted at a temperature higher than room temperature. In this case, however, care should be taken so as not to cause explosion if a peroxide is used. In cases where the reaction typically proceeds with severity, it is desirable to cool the reaction mixture at a temperature lower than room temperature. Although the time of the oxidation treatment is appropriately selected depending on the concentration of the oxidizing agent and the reaction temperature, it is usually 10 minutes to 5 hours. After the oxidation treatment, the porous membrane may be washed with water and/or alcohol to obtain an oxidized porous membrane. Although the oxidation treatment may be performed either before or after the preparation of the composite membrane by forming an active layer on the polyphenylenesulfide sulfone porous membrane, since the active layer may be adversely affected by the oxidation treatment, it is preferred to perform the oxidation treatment before forming the active layer. The active layer having reverse osmosis property is formed of a cross-linked polyamide prepared by interfacial polycondensation. The method for forming the active layer made of a cross-linked polyamide by interfacial polycondensation is well-known as a method for producing conventional composite reverse osmosis membranes. That is, the active layer may be formed by interfacially polycondensing a multifunctional amine and a multifunctional acid halide. As the multifunctional amine compound, amine compounds with di- or poly valence may be employed. Representative amine compounds include m-phenylenediamine, 1,3,5-triaminobenzene, piperazine, polyethyleneimine and ethylenediamine. As the multifunctional acid halide, for example, acid halides of 1,3,5-benzenetricarboxylic acid, terephthalic acid, isophthalic acid, 1,3,5-cyclohexanetricarboxylic acid, cyclohexanedicarboxylic acid, adamantane tetracarboxylic acid and furandicarboxylic acid may be employed. Although the cross-linked polyamide constituting the active layer is not restricted, having regard to the separation characteristics and permeation characteristics, cross-linked polyamides comprising as a major constituent a cross-linked aromatic polyamide or cross-linked piperazine polyamide are preferred. The active layer of the composite reverse osmosis membrane may be formed by applying an aqueous solution containing the multifunctional amine on the substrate membrane, and then applying thereon a solution containing the multifunctional acid halide in an organic solvent which is immiscible with water so as to carry out the interfacial polycondensation reaction. The optimum concentration of the amino compound in the aqueous multifunctional amine solution varies depending on the compound, but it is usually 0.1 - 10% by weight, preferably 0.5 - 5.0% by weight. The aqueous solution may contain, for example, a surfactant, organic solvent or antioxidant as long as they do not hinder the reaction. The application of the aqueous amine solution on the surface of the porous substrate may be conducted by any appropriate method as long as the surface of the microporous substrate is covered with the aqueous amine solution uniformly and continuously. For example, the aqueous solution may be coated on the surface of the porous membrane or the porous membrane may be immersed in the aqueous solution. The aqueous amine solution applied in excess is removed in a liquid-removing step. The excess solution may be removed by, for example, vertically holding the membrane so that the excess solution naturally drops from the membrane. It is preferable not to leave a drop on the membrane. The membrane may be dried after the excess solution is removed, although this is not necessary. Then the organic solution of the above-described polyfunctional acid halide in the organic solution is applied to the membrane to form the ultra-thin membrane containing cross-linked polyamide as the major component by the interfacial polycondensation. The concentration of the polyfunctional acid halide in the organic solution may preferably be 0.01 - 10% by weight, more preferably 0.02 - 2% by weight. In some cases, it is preferred that the organic solution contain an acylation catalyst such as DMF since the interfacial polycondensation is enhanced. The organic solvent is required to be immiscible with water, to dissolve the acid halide and not to destroy the porous membrane. Any organic solvent satisfying these requirements, which is inert to the amino compound and to the acid halide, may be employed. Preferred examples of the organic solvent include hydrocarbons, trichlorotrifluoroethane and the like. Having regard to the reaction rate and the volatility of the solvent, n-hexane and trichlorotrifluoroethane are preferred, and in view of the inflammability of the solvent, trichlorotrifluoroethane is most preferred. The polyfunctional acid halide may be contacted with the aqueous phase of the amino compound in the same manner as the application of the aqueous amino compound solution on the porous membrane. The thus prepared composite membrane exhibits satisfactory performance as it is. However, by immersing the thus prepared composite membrane in an aqueous solution containing chlorine with a pH of 6 - 13, the performance of the membrane, especially the salt rejection and the water flux may be improved. Examples of the chlorine-generating reagent include chlorine gas, bleaching powder, sodium hypochlorite, chlorine dioxide, Chloramine B, Chloramine T, Halazone, dichlorodimethylhydantoin, and isocyanuric acid chloride as well as salts thereof. The concentration thereof may preferably be determined based on the oxidation power thereof. Among the above-mentioned chlorine-generating reagents, aqueous sodium hypochlorite solution is most preferred in view of its ease of handling. There is an important relationship between the oxidation power and pH of the chlorine-containing aqueous solution. For example, in the case of an aqueous sodium hypochlorite solution, if the pH is less than 6, the solution does not have a sufficient oxidation power and if the pH is more than 13, the amide bond may be hydrolyzed. Examples Embodiments of the present invention will now be described in more detail by way of examples thereof. Reference Example 1 The aqueous peracetic acid solution used herein was prepared by adding 22.8 ml of 30 wt% aqueous hydrogen peroxide solution and 1.6 ml of concentrate sulfuric acid to 75.6 ml of acetic acid and leaving the resulting mixture to stand at room temperature (20 - 25°C) for one day. Reference Example 2 Twenty grams of polyphenylenesulfide sulfone (weight average molecular weight: 31,600) having repeating units represented by the formula ((Ph-S)(Ph-SO 2 )) was added to 80 g of N-methyl-2-pyrrolidone and the resulting mixture was heated at 180°C for 1 hour to dissolve the polyphenylenesulfide sulfone. The obtained solution was cooled to 50°C, and insoluble materials were removed by filtration through a polytetrafluoroethylene membrane filter with a pore size of 10 µm to obtain a solution for film-forming. The solution for film-forming (temperature: 50°C) was cast on a glass plate to a thickness of 150 µm and then the glass plate was immediately immersed in pure water at 25°C, followed by leaving the glass plate to stand in the pure water for 5 minutes to obtain a porous poly(phenylenesulfide sulfone) substrate. The thus obtained porous membrane was immersed in the peracetic acid prepared in Reference Example 1 for 3 hours at room temperature (25°C). Analysis of the thus obtained porous membrane by IR and NMR revealed that the polymer constituting the porous membrane contained 90 mol% of a repeating unit of the formula ((Ph-SO 2 )(Ph-SO 2 )) and 10 mol% of a repeating unit of the formula ((Ph-S)(Ph-SO 2 )). Reference Example 3 Poly(phenylenesulfide sulfone)(PPSS) was synthesized by the following process: That is, to an autoclave of about 1 liter equipped with a thermometer, pressure gauge, stirrer, and an external heater, 154.7 g of bis-(4-chlorophenyl)sulfone, 56.5 g of sodium carbonate, 43.7 g of sodium acetate, 50.7 g of sodium hydrogen sulfide (in the form of a 59.0 wt% aqueous solution), 21.7 g of N-methyl-2-pyrrolidone (NMP) and 14.4 g of deionized water were supplied. The mixture was heated from 25°C to 200°C with stirring and was stirred for 3 hours at 200°C. A mixture of 160 ml of NMP and 26.7 ml of deionized water was then added to the autoclave. Stirring was continued until the temperature of the mixture had risen to about 150°C. The reaction mixture in the form of solid granules was removed from the reaction vessel and the liquid was aspirated. The solid substance was washed with hot deionized water (about 90°C, about 600 ml), filtered and rinsed once on the filter. These steps were repeated twice and the mixture was finally rinsed with cold deionized water so as to remove water-soluble impurities. To a one liter autoclave, 40 g of the thus purified and recovered polymer, 400 g of deionized water and 4.0 g of zinc acetate [Zn(C 2 H 3 O 2 ·2H 2 O) were supplied. The autoclave was then equipped with a stirrer, heater/cooler, thermometer and pressure gauge. The mixture of polymer/aqueous zinc acetate solution was heated to 185°C with stirring and the mixture was kept at this temperature for another one hour with stirring. The mixture was then cooled to room temperature and the recovered polymer was once washed with hot water (about 90°C, about 400 ml) with stirring. The recovered polymer was dried at 160°C under reduced pressure. The weight average molecular weight of the polymer was 31,600. Infrared absorption spectrum analysis revealed that the polymer had a chemical structure of the formula (Ph-S-Ph-SO 2 ) q This polymer is hereinafter referred to as polyphenylenesulfide sulfone (PPSS) for short. To 85 g of dry N-methylpyrrolidone, 15 g of the thus obtained PPSS was added. After the atmosphere of the vessel containing this mixture was changed to nitrogen, the mixture was heated to 180°C to dissolve the polymer. Insoluble materials were removed by filtering the mixture through a polytetrafluoroethylene membrane filter with a pore size of 1 µm. The thus obtained solution was cast onto a glass plate to an average thickness of 150 µm at room temperature (20°C) and the glass plate was then immediately immersed in water (25°C) to obtain a porous membrane. Reference Example 4 Peracetic acid solution was prepared by adding 22.8 ml of 30% aqueous hydrogen peroxide solution and 1.6 ml of concentrate sulfuric acid to 75.6 ml of acetic acid and leaving the resulting mixture to stand for one day. In order to prepare a porous membrane the same procedure as in Reference Example 2 was repeated except that a taffeta made of polyester fibers (both the warps and wefts consisted of multifilament yarn of 150 deniers, weaving density: 90 warps/inch, 67 wefts/inch, thickness: 160 µm) was fixed on the glass plate and the solution for film-forming was cast on the taffeta, to obtain the fiber-reinforced porous membrane. The porous membrane thus obtained was immersed in peracetic acid solution for 3 hours and then washed with water. Examples of the composite membranes for reverse osmosis will now be described. The performance of the composite membranes was evaluated based on the salt rejection and water flux measured by ordinary methods using 1500 ppm of NaCl at 15 atm., 25°C. Example 1 On a polyphenylenesulfide non-woven fabric with a thickness of 100 µm, 16 wt% polyphenylenesulfide sulfone solution in dimethylimidazolidinone (DMI) was applied to a thickness of 70 µm at room temperature. The fabric was then immersed in distilled water at room temperature so as to coagulate the solution, thereby obtaining a polyphenylenesulfide sulfone porous substrate reinforced with polyphenylenesulfide non-woven fabric. The thus obtained membrane had a rejection ratio against polyethylene glycol with a molecular weight of 100,000 of about 90% and water flux of about 2 m 3 /m 2 ·day (1 atm, 25°C, 1000 ppm aqueous polyethylene glycol solution). The porous membrane thus obtained was immersed in an aqueous solution containing 1% by weight of m-phenylenediamine and 1% by weight of 1,3,5-triaminobenzene for 3 minutes. After removing the excess aqueous solution, a solution containing 0.05% by weight of terephthalic acid chloride and 0.05% by weight of trimesic acid chloride in trifluorotrichloroethane was applied on the membrane to form an ultra-thin membrane of a cross-linked aromatic polyamide. The thus obtained composite membrane had a salt rejection of about 99% and a water flux of about 1 m 3 /m 2 ·day. Example 2 The same procedure as in Example 1 was repeated except that a polyphenylenesulfide sulfone porous substrate membrane oxidized by peracetic acid solution was used. The obtained composite membrane had a salt rejection of about 98% and a water flux of about 1 m 3 /m 2 ·day. Comparative Example The same procedure as in Example 1 was repeated except that a polysulfone porous substrate membrane was used. The obtained composite membrane had a salt rejection of about 99% and a water flux of about 1 m 3 /m 2 ·day. The composite membrane was immersed in a suspension of water/trichloroethylene for one day, and then the suspension was replaced with water. As a result, the polysulfone porous substrate membrane was broken and the membrane did not retain the form of a composite membrane. The composite membrane of the present invention has excellent separation ability, permeability, organic solvent resistance and heat resistance, and can be used as a composite semipermeable membrane for reverse osmosis. Thus, the composite membrane of the present invention can be used for the treatment of waste liquids in the food industry, polymer industry and petroleum chemical industry, to which conventional composite membranes cannot be applied. Thus, the composite membrane of the present invention will greatly contribute to separation processes utilizing membranes.

Claims: A composite membrane comprising a porous membrane of a polymeric material consisting essentially of a polymer having phenylenesulfide-phenylenesulfone repeating units adjacent to one another, which polymer has n said repeating units and which said repeating unit is represented by the formula (I) (Ph-S-Ph-SO 2 ) wherein Ph represents a phenyl group and n represents a whole number and, deposited on the porous membrane, an active layer of a material selected from cross-linked polyamides prepared by interfacial polycondensation. A composite membrane according to claim 1, wherein the active layer is capable of reverse osmosis and the active layer material is a said cross-linked polyamide comprising as a major constituent a cross-linked aromatic polyamide or a cross-linked piperazine polyamide. A composite membrane according to claim 1 or claim 2, which is in the form of a flat membrane, and wherein the composite membrane further comprises a woven or non-woven fabric on which the porous membrane and active layer are laminated, which fabric is made of a polymer selected from polyesters, polyamides, polyethylene, polypropylene and polyphenylenesulfide. A composite membrane comprising an oxidized porous membrane prepared by oxidizing a porous membrane of a polymeric material consisting essentially of a polymer having phenylenesulfide-phenylenesulfone repeating units adjacent to one another, which polymer has n said repeating units and which said repeating unit is represented by the formula (I) (Ph-S-Ph-SO 2 ) wherein Ph represents a phenyl group and n represents a whole number, so that a part of the sulfide bonds are oxidised to sulfone bonds and, deposited on the porous membrane, an active layer of a material selected from cross-linked polyamides prepared by interfacial polycondensation. A composite membrane according to claim 4, wherein the oxidation of the porous membrane is carried out by immersing the porous membrane in an oxidizing agent selected from peracetic acid, chloroperbenzoic acid and tetrabutylammonium hypochlorite. Use, for reverse osmosis, of a composite membrane comprising a porous membrane of a polymeric material consisting essentially of a polymer having phenylenesulfide-phenylenesulfone repeating units adjacent to one another, which polymer has n said repeating units and which said repeating unit is represented by the formula (I) (Ph-S-Ph-SO 2 ) wherein Ph represents a phenyl group and n represents a whole number and, deposited on the porous membrane, an active layer of a material capable of effecting reverse osmosis, which material is a cross-linked polyamide prepared by interfacial polycondensation. A method of preparing a composite membrane, which method comprises the steps of forming a porous membrane of a polymeric material consisting essentially of a polymer having phenylenesulfide-phenylenesulfone repeating units adjacent to one another, which polymer has n said repeating units and which said repeating unit is represented by the formula (I) (Ph-S-Ph-SO 2 ) wherein Ph represents a phenyl group and n represents a whole number, optionally oxidising the polyphenylene sulfone sulfide polymer of the porous membrane so that a part of the sulfide bonds are oxidised to sulfone bonds and either prior or subsequently to any such oxidation, depositing on the porous membrane an active layer of a material selected from cross-linked polyamides prepared by interfacial polycondensation. A method according to claim 7, which includes the said oxidation step and which oxidation step is carried out by immersing the porous membrane in an oxidizing agent selected from peracetic acid, chloroperbenzoic acid and tetrabutylammonium hypochlorite.

Inventors: HIMESHIMA YOSHIO, KURIHARA MASARU, SHIRO KUNIYASU, UEMURA TADAHIRO, WATANABE TETSUO, YAMADA SHINICHI, HIMESHIMA, YOSHIO, KURIHARA, MASARU, SHIRO, KUNIYASU, UEMURA, TADAHIRO, WATANABE, TETSUO, YAMADA, SHINICHI, HIMESHIMA, YOSHIO, D-162, HOKUENRYO, KURIHARA, MASARU, 2-56, OHIRA 2-CHOME, SHIRO, KUNIYASU, A1-34, MINAMIMACHI, UEMURA, TADAHIRO, MAIZON YAMASHINA, WATANABE, TETSUO, C-338, HOKUENRYO, YAMADA, SHINICHI, 3-1-112, SONOYAMA 2-CHOME
Applicants: TORAY INDUSTRIES, TORAY INDUSTRIES, INC.
Application year: 1991
Main classification: B01D71
IPC codes: B01D69, B01D71