Abstract: Presented is a method for preparing a gas separation membrane system. This method involves depositing a membrane layer of gas-selective metal upon a tubular porous support followed by annealing the resulting layer of gas-selective metal. The resulting annealed membrane layer of gas-selective material is polished under a controlled polishing condition with an abrading medium that includes a structured abrasive article comprising a backing having bonded thereto an abrasive layer comprising a plurality of shaped abrasive composites that comprise abrasive grains dispersed in a polymeric binder. Another layer of gas-selective metal is then deposited upon the tubular porous support. The cycle of annealing, polishing and depositing is repeated through one or more cycles until a leak-tight membrane system is provided.

Abstract: Methods for preparing a gas separation membrane system can include depositing a gas-selective membrane layer upon a surface of a tubular porous support, annealing the gas-selective membrane layer to form an annealed gas-selective membrane layer, polishing the annealed gas-selective membrane layer under a controlled polishing condition to form an abraded membrane surface, depositing another gas-selective membrane layer upon the abraded membrane surface of the tubular porous support, and successively iterating the annealing, polishing and depositing operations until a leak-tight membrane system is formed. The controlled polishing condition comprises utilizing a rotary fibrous buff that includes a plurality of abrasive particles adhered to a fibrous support with a polymeric binder.