Urea methanolysis
is a green alternative to synthesize dimethyl
carbonate (UM-to-DMC). However, it is strongly challenged by the generated
NH3 induced thermodynamic equilibrium limitation and the
azeotropic products’ separation. Herein, these predicaments
are well-relieved by introducing membranes in both reaction and product
separation. An NH3 permselective membrane reactor (MR)
based on modified SAPO-34 membrane is successfully realized for UM-to-DMC.
The permselectivity and acidity of the SAPO-34 membrane are significantly
adjusted to cater the strict molecular sieving of NH3/methanol
and chemical inertness upon the reaction. The MR exhibits excellent
reactant conversion and DMC selectivity, resulting in >139% higher
DMC yield than that of the nonmembrane reactor, due to in
situ removal of NH3 by the membrane. The MR also
demonstrates reliable chemical, thermal, and mechanical stability
during >2000 h. Moreover, the regular SAPO-34 membrane with controlled
thickness presents remarkable separation performance for the methanol–DMC
azeotrope, in which the methanol–DMC separation factors and
the methanol permeance are 1–2 orders of magnitude higher than
those of the polymeric membranes. This study suggests the great potential
that integration of such membranes offers for process intensification,
energy savings, and efficiency improvement in a series of urea alcoholysis
and even other NH3 releasing reactions.