Gas separation for industrial, energy, and environmental applications requires low energy consumption and small footprint technology to minimize operating and capital costs for the processing of large volumes of gases. Among the separation methods currently being used, like distillation, amine scrubbing, and pressure and temperature swing adsorption, membrane-based gas separation has the potential to meet these demands. The key component, the membrane, must then be engineered to allow for high gas flux, high selectivity, and chemical and mechanical stability at the operating conditions of feed composition, pressure, and temperature. Among the new type of membranes studied that show promising results are the inorganic-based and the metal-organic framework-based mixed-matrix membranes (MOF-MMMs). A MOF is a unique material that offers the possibility of tuning the porosity of a membrane by introducing diffusional channels and forming a compatible interface with the polymer. This review details the origins of these membranes and their evolution since the first inorganic/polymer and MOF/polymer MMMs were reported in the open literature. The most significant advancements made in terms of materials, properties, and testing conditions are described in a chronological fashion.

The use of immiscible polymer blends in gas separations is limited due to uncontrollable phase separation. In contrast, compatibilized immiscible polymer blends can be used as precursors with controlled morphologies that allow for a unique pore architecture. Herein, an immiscible polymer blend (1:1) comprising polybenzimidazole (PBI) and the copolyimide 6FDA-DAM:DABA [3:2], derived from reacting 4,4-(hexafluoroisopropylidene)diphthalic anhydride (6FDA) with 2,4,6-trimethyl-1,3-phenylenediamine (DAM) and 3,5-diaminobenzoic acid (DABA), were combined with durene diamine as a compatibilizer. The compatibilizer helped reduce the 6FDD domain sizes from 5.6 µm down to 0.77 µm and induced a more even 6FDA distribution and the formation of continuous thin-selective PBI layers. The carbon–carbon composite membranes derived from the compatibilized immiscible polymer blends showed a 3-fold increase in both H₂ permeability and H₂/CO₂ selectivity compared to the membranes derived from non-compatibilized polymer blends. The H₂ permeability of the compatibilized immiscible polymer blends increased from 3.6 to 27 Barrer, and their H₂/CO₂ selectivity increased from 7.2 to 20. The graphitic domain size of the carbon–carbon composite membranes derived from the polymer blends also increased from 6.3 nm for the non-compatibilized blend to 10.0 nm for the compatibilized blend.

Carbon molecular sieve membranes (CMSMs) were prepared by carbonizing the high free volume polyimide BTDA-BAF that is obtained from the reaction of benzophenone-3,3′,4,4′-tetracarboxylic dianhydride (BTDA) and 9,9-bis(4-aminophenyl) fluorene (BAF). The bulky cardo groups prevented a tight packing and rotation of the chains that leads to high permeabilities of their CMSMs. The incorporation of metal–organic polyhedra 18 (MOP-18, a copper-based MOP) in the BTDA-BAF polymer before pyrolysis at 550 °C prevented the collapse of the pores and the aging of the CMSMs. It was found that upon decomposition of MOP-18, a distribution of copper nanoparticles minimized the collapse of the graphitic sheets that formed the micropores and mesopores in the CMSM. The pillared CMSMs displayed CO₂ and CH₄ permeabilities of 12,729 and 659 Barrer, respectively, with a CO₂/CH₄ selectivity of 19.3 after 3 weeks of aging. The permselectivity properties of these membranes was determined to be at the 2019 Robeson upper bound. In contrast, the CMSMs from pure BTDA-BAF aged three times faster than the CMSMs from MOP-18/BTDA-BAF and exhibited lower CO₂ and CH₄ permeabilities of 5337 and 573 Barrer, respectively, with a CO₂/CH₄ selectivity of 9.3. The non-pillared CMSMs performed below the upper bound.

Carbon molecular sieve membranes (CMSMs) provide a means to greatly improve gas separations. CMSMs have a pore size distribution comprising micropores and ultramicropores which provide high flux and high selectivity, enabling them to outperform polymeric membranes. CMSMs, however, suffer from physical aging that results from the collapse of the pores that severely reduces their gas permeability. Therefore, reducing physical aging of CMSMs is an important step in the development of these types of materials. In this work, a method for reducing physical aging through the incorporation of metal nanoparticles that serve as a structural scaffold for the membrane pore structure is presented. The pore structure in CMSMs is dependent upon the polymeric precursor, and thus the support system incorporated must be tailored. The copper nanoparticles were formed in situ from soluble, copper-based metal–organic polyhedra 18 (MOP-18) dispersed into Matrimid^® 5218, a low free volume polymer. The size (2 to 20 nm) and shape (sphere, rods) of the copper particles were refined by adjusting MOP-18 loading, pyrolysis temperature, and soaking time. The Cu-pillared Matrimid^® 5218 CMSMs from this work showed no decline in permeability or selectivity for methane (107 Barrer) and carbon dioxide (1785 Barrer) over a period of 21 d. The results suggest that tailored metal pillars can suppress physical aging in CMSMs, thereby enhancing their long-term stability and applicability in gas separations.