Ultrahigh oxygen permeation flux through supported Ba0.5Sr0.5Co0.8Fe0.2O3−δ membranes

Co2MnO4/Ce0.8Tb0.2O2-δ Dual-Phase Membrane Material with High CO2 Stability and Enhanced Oxygen Transport for Oxycombustion Processes

Oxygen transport membranes (OTMs) are a promising oxygen production technology with high energy efficiency due to the potential for thermal integration. However, conventional perovskite materials of OTMs are unstable in CO2 atmospheres, which limits their applicability in oxycombustion processes. On the other hand, some dual-phase membranes are stable in CO2 and SO2 without permanent degradation. However, oxygen permeation is still insufficient; therefore, intensive research focuses on boosting oxygen permeation. Here, we present a novel dual-phase membrane composed of an ion-conducting fluorite phase (Ce0.8Tb0.2O2-δ, CTO) and an electronic-conducting spinel phase (Co2MnO4, CMO). CMO spinel exhibits high electronic conductivity (60 S·cm-1 at 800 °C) compared to other spinels used in dual-phase membranes, i.e., 230 times higher than that of NiFe2O4 (NFO). This higher conductivity ameliorates gas-solid surface exchange and bulk diffusion mechanisms. By activating the bulk membrane with a CMO/CTO porous catalytic layer, it was possible to achieve an oxygen flux of 0.25 mL·min-1·cm-2 for the 40CMO/60CTO (%vol), 680 μm-thick membrane at 850 °C even under CO2-rich environments. This dual-phase membrane shows excellent potential as an oxygen transport membrane or oxygen electrode under high CO2 and oxycombustion operation.

Perovskite Membranes: Advancements and Challenges in Gas Separation, Production, and Capture

Perovskite membranes have gained considerable attention in gas separation and production due to their unique properties such as high selectivity and permeability towards various gases. These membranes are composed of perovskite oxides, which have a crystalline structure that can be tailored to enhance gas separation performance. In oxygen enrichment, perovskite membranes are employed to separate oxygen from air, which is then utilized in a variety of applications such as combustion and medical devices. Moreover, perovskite membranes are investigated for carbon capture applications to reduce greenhouse gas emissions. Further, perovskite membranes are employed in hydrogen production, where they aid in the separation of hydrogen from other gases such as methane and carbon dioxide. This process is essential in the production of clean hydrogen fuel for various applications such as fuel cells and transportation. This paper provides a review on the utilization and role of perovskite membranes in various gas applications, including oxygen enrichment, carbon capture, and hydrogen production.

Ion-Conducting Ceramic Membrane Reactors for the Conversion of Chemicals

Ion-conducting ceramic membranes, such as mixed oxygen ionic and electronic conducting (MIEC) membranes and mixed proton-electron conducting (MPEC) membranes, have the potential for absolute selectivity for specific gases at high temperatures. By utilizing these membranes in membrane reactors, it is possible to combine reaction and separation processes into one unit, leading to a reduction in by-product formation and enabling the use of thermal effects to achieve efficient and sustainable chemical production. As a result, membrane reactors show great promise in the production of various chemicals and fuels. This paper provides an overview of recent developments in dense ceramic catalytic membrane reactors and their potential for chemical production. This review covers different types of membrane reactors and their principles, advantages, disadvantages, and key issues. The paper also discusses the configuration and design of catalytic membrane reactors. Finally, the paper offers insights into the challenges of scaling up membrane reactors from experimental stages to practical applications.

A Review of Oxygen Carrier Materials and Related Thermochemical Redox Processes for Concentrating Solar Thermal Applications

Redox materials have been investigated for various thermochemical processing applications including solar fuel production (hydrogen, syngas), ammonia synthesis, thermochemical energy storage, and air separation/oxygen pumping, while involving concentrated solar energy as the high-temperature process heat source for solid-gas reactions. Accordingly, these materials can be processed in two-step redox cycles for thermochemical fuel production from H₂O and CO₂ splitting. In such cycles, the metal oxide is first thermally reduced when heated under concentrated solar energy. Then, the reduced material is re-oxidized with either H₂O or CO₂ to produce H₂ or CO. The mixture forms syngas that can be used for the synthesis of various hydrocarbon fuels. An alternative process involves redox systems of metal oxides/nitrides for ammonia synthesis from N₂ and H₂O based on chemical looping cycles. A metal nitride reacts with steam to form ammonia and the corresponding metal oxide. The latter is then recycled in a nitridation reaction with N₂ and a reducer. In another process, redox systems can be processed in reversible endothermal/exothermal reactions for solar thermochemical energy storage at high temperature. The reduction corresponds to the heat charge while the reverse oxidation with air leads to the heat discharge for supplying process heat to a downstream process. Similar reversible redox reactions can finally be used for oxygen separation from air, which results in separate flows of O₂ and N₂ that can be both valorized, or thermochemical oxygen pumping to absorb residual oxygen. This review deals with the different redox materials involving stoichiometric or non-stoichiometric materials applied to solar fuel production (H₂, syngas, ammonia), thermochemical energy storage, and thermochemical air separation or gas purification. The most relevant chemical looping reactions and the best performing materials acting as the oxygen carriers are identified and described, as well as the chemical reactors suitable for solar energy absorption, conversion, and storage.

Thermal Swing Reduction-Oxidation of Me(Ba, Ca, or Mg)SrCoCu Perovskites for Oxygen Separation from Air

The climate change impact associated with greenhouse gas emissions is a major global concern. This work investigates perovskite compounds for oxygen separation from air to supply oxygen to oxyfuel energy systems to abate these significant environmental impacts. The perovskites studied were Me0.5Sr0.5Co0.8Cu0.2O3−δ (MeSCC) where the A-site substitution was carried out by four different cations (Me = Ca, Mg, Sr, or Ba). SEM analysis showed the formation of small particle (<1 µm) aggregates with varying morphological features. XRD analysis confirmed that all compounds were perovskites with a hexagonal phase. Under reduction and oxidation reactions (redox), Ba and Ca substitutions resulted in the highest and lowest oxygen release, respectively. In terms of real application for oxygen separation from air, Ba substitution as BaSCC proved to be preferable due to short temperature cycles for the uptake and release of oxygen of 134 °C, contrary to Ca substitution with long and undesirable temperature cycles of 237 °C. As a result, a small air separation unit of 0.66 m3, containing 1000 kg of BaSCC, can produce 18.5 ton y−1 of pure oxygen by using a conservative heating rate of 1 °C min−1. By increasing the heating rate by a further 1 °C min−1, the oxygen production almost doubled by 16.7 ton y−1. These results strongly suggest the major advantages of short thermal cycles as novel designs for air separation. BaSCC was stable under 22 thermal cycles, and coupled with oxygen production, demonstrates the potential of this technology for oxyfuel energy systems to reduce the emission of greenhouse gases.

Development of an Oxy-Fuel Combustion System in a Compression-Ignition Engine for Ultra-Low Emissions Powerplants Using CFD and Evolutionary Algorithms

This study uses an optimization approach for developing a combustion system in a compression–ignition engine that is able to operate under oxy-fuel conditions, and produces mainly CO2 and H2O as exhaust gases. This is achieved because the combustion concept uses pure oxygen as an oxidizer, instead of air, avoiding the presence of nitrogen. The O2 for the combustion system can be obtained by using a mixed ionic–electronic conducting membrane (MIEC), which separates the oxygen from the air onboard. The optimization method employed maximizes the energy conversion of the system, reducing pollutant emissions (CxHy, particulate matter, and carbon monoxides) to levels near zero. The methodology follows a novel approach that couples computational fluid dynamics (CFD) and particle swarm optimization (PSO) algorithms to optimize the complete combustion system in terms of engine performance and pollutant generation. The study involves the evaluation of several inputs that govern the combustion system design in order to fulfill the thermo-mechanical constraints. The parameters analyzed are the piston bowl geometry, fuel injector characteristics, air motion, and engine settings variables. Results evince the relevance of the optimization procedure, achieving very low levels of gaseous pollutants (CxHy and CO) in the optimum configuration. The emissions of CO were reduced by more than 10% while maintaining the maximum in-cylinder pressure within the limit imposed for the engine. However, indicated efficiency levels are compromised if they are compared with an equivalent condition operating under conventional diesel combustion.

Development of a Membrane Module Prototype for Oxygen Separation in Industrial Applications

The integration of oxygen transport membranes in industrial processes can lead to energy and economic advantages, but proof of concept membrane modules are highly necessary to demonstrate the feasibility of this technology. In this work, we describe the development of a lab-scale module through a comprehensive study that takes into consideration all the relevant technological aspects to achieve a prototype ready to be operated in industrial environment. We employed scalable techniques to manufacture planar La0.6Sr0.4Co0.2Fe0.8O3-δ membrane components suitable for the application in both 3- and 4-end mode, designed with a geometry that guarantees a failure probability under real operating conditions as low as 2.2 × 10−6. The asymmetric membranes that act as separation layers showed a permeation of approx. 3 NmL/min/cm2 at 900 °C in air/He gradient, with a remarkable stability up to 720 h, and we used permeation results to develop a CFD model that describes the influence of the working conditions on the module performance. The housing of the membrane component is an Inconel 625 case joined to the membrane component by means of a custom-developed glass–ceramic sealant that exhibited a remarkable thermo-chemical compatibility both with metal and ceramic, despite the appearance of chemical strain in LSCF at high temperature. The multi-disciplinary approach followed in this work is suitable to be adapted to other module concepts based on membrane components with different dimensions, layouts or materials.

Bubble nucleation in core-shell structured molten oxide-based membranes with combined diffusion-bubbling oxygen mass transfer: experiment and theory

Oxygen-selective membranes are likely to play a leading part in the future separation processes relevant to energy engineering. A newly developed molten copper and vanadium oxide-based diffusion-bubbling membrane with core-shell structure and fast combined oxygen mass transfer is a promising candidate for efficient oxygen separation. In this work, the oxygen bubble nucleation and transport properties of the diffusion-bubbling membrane were experimentally and theoretically studied. Bubble size distribution and cumulative oxygen flux have been plotted as functions of oxygen partial pressure. The relationship between the bubble density, oxygen partial pressure, and oxygen permeation flux was established. The oxygen flux and bubble density vary in the ranges of 3.2 × 10^-8-1.4 × 10^-7 mol cm^-2 s^-1 and 1.3 × 10¹³-5.8 × 10¹³ m^-3 at ΔP_O2 = 0.1-0.75 atm, respectively. The mechanisms of homogeneous, heterogeneous, pseudo-classical and non-classical nucleation are reviewed within the framework of the Cahn-Hilliard model. It is shown that the homogeneous nucleation mechanism is most likely in the membrane core. The estimated values of the interfacial tension, energy barrier, and rate nucleation are 0.02 J m^-2, 5 kT, and 4 × 10²⁹ m^-3 s^-1, respectively.

Oxygen-Selective Diffusion-Bubbling Membranes with Core-Shell Structure: Bubble Dynamics and Unsteady Effects

Oxygen is the second-largest-volume industrial gas that is mainly produced using cryogenic air separation. However, the state-of-the-art cryogenic technology thermodynamic efficiency has approached a theoretical limit as near as is practicable. Therefore, there is stimulus to develop an alternative technology for efficient oxygen separation from air. Mixed ionic electronic-conducting (MIEC) ceramic membrane-based oxygen separation technology could become this alternative, but commercialization aspects, including cost, have revealed inadequacies in ceramic membrane materials. Currently, diffusion-bubbling molten oxide membrane-based oxygen separation technology is being developed. It is a potentially disruptive technology that would propose an improvement in oxygen purity and a reduction in capital costs. Bubbles play an important role in ensuring the oxygen mass transfer in diffusion-bubbling membranes. However, there is not sufficient understanding of the bubble dynamics. This understanding is important to be able to control transport properties of these membranes and assess their potential for technological application. The aim of this feature article is to highlight the progress made in developing this understanding and specify the directions for future research.

Development and Proof of Concept of a Compact Metallic Reactor for MIEC Ceramic Membranes

The integration of mixed ionic–electronic conducting separation membranes in catalytic membrane reactors can yield more environmentally safe and economically efficient processes. Concentration polarization effects are observed in these types of membranes when O₂ permeating fluxes are significantly high. These undesired effects can be overcome by the development of new membrane reactors where mass transport and heat transfer are enhanced by adopting state-of-the-art microfabrication. In addition, careful control over the fluid dynamics regime by employing compact metallic reactors equipped with microchannels could allow the rapid extraction of the products, minimizing undesired secondary reactions. Moreover, a high membrane surface area to catalyst volume ratio can be achieved. In this work, a compact metallic reactor was developed for the integration of mixed ionic–electronic conducting ceramic membranes. An asymmetric all-La_0.6Sr_0.4Co_0.2Fe_0.8O_3–δ membrane was sealed to the metallic reactor by the reactive air brazing technique. O₂ permeation was evaluated as a proof of concept, and the influence of different parameters, such as temperature, sweep gas flow rates and oxygen partial pressure in the feed gas, were evaluated.

High-Throughput Computational Screening of Cubic Perovskites for Solid Oxide Fuel Cell Cathodes

It is a present-day challenge to design and develop oxygen-permeable solid oxide fuel cell (SOFC) electrode and electrolyte materials that operate at low temperatures. Herein, by performing high-throughput density functional theory calculations, oxygen vacancy formation energy, E_vac, data for a pool of all-inorganic ABO₃ and A^I_0.5A^II_0.5BO₃ cubic perovskites is generated. Using E_vac data of perovskites, the area-specific resistance (ASR) data, which is related to both oxygen reduction reaction activity and selective oxygen ion conductivity of materials, is calculated. Screening a total of 270 chemical compositions, 31 perovskites are identified as candidates with properties that are between those of state-of-the-art SOFC cathode and oxygen permeation components. In addition, an intuitive approach to estimate E_vac and ASR data of complex perovskites by using solely the easy-to-access data of simple perovskites is shown, which is expected to boost future explorations in the perovskite material search space for genuinely diverse energy applications.

Oxygen Transport Membranes for Efficient Glass Melting

Glass manufacturing is an energy-intensive process in which oxy-fuel combustion can offer advantages over the traditional air-blown approach. Examples include the reduction of NO_x and particulate emissions, improved furnace operations and enhanced heat transfer. This paper presents a one-dimensional mathematical model solving mass, momentum and energy balances for a planar oxygen transport membrane module. The main modelling parameters describing the surface oxygen kinetics and the microstructure morphology of the support are calibrated on experimental data obtained for a 30 μm thick dense La_0.6Sr_0.4Co_0.2Fe_0.8O_3-δ (LSCF) membrane layer, supported on a 0.7 mm porous LSCF structure. The model is then used to design and evaluate the performance of an oxygen transport membrane module integrated in a glass melting furnace. Three different oxy-fuel glass furnaces based on oxygen transport membrane and vacuum swing adsorption systems are compared to a reference air-blown unit. The analysis shows that the most efficient membrane-based oxyfuel furnace cuts the energy demand by ~22% as compared to the benchmark air-blown case. A preliminary economic assessment shows that membranes can reduce the overall glass production costs compared to oxyfuel plants based on vacuum swing adsorption technology.

Asymmetric LSCF Membranes Utilizing Commercial Powders

Powders of constant morphology and quality are indispensable for reproducible ceramic manufacturing. In this study, commercially available powders were characterized regarding their microstructural properties and screened for a reproducible membrane manufacturing process, which was done by sequential tape casting. Basing on this, the slurry composition and ratio of ingredients were systematically varied in order to obtain flat, crack-free green tapes suitable for upscaling of the manufacturing process. Debinding and sintering parameters were adjusted to obtain defect-free membranes with diminished bending. The crucial parameters are the heating ramp, sintering temperature, and dwell time. The microstructure of the asymmetric membranes was investigated, leading to a support porosity of approximately 35% and a membrane layer thickness of around 20 µm. Microstructure and oxygen flux are comparable to asymmetric La_0.6Sr_0.4Co_0.2Fe_0.8O_3-δ (LSCF) membranes manufactured from custom-made powder, showing an oxygen flux of > 1 mLcm^-2min at 900 °C in air/Ar gradient.

Microstructural and Interfacial Designs of Oxygen-Permeable Membranes for Oxygen Separation and Reaction-Separation Coupling

Mixed ionic-electronic conducting oxygen-permeable membranes can rapidly separate oxygen from air with 100% selectivity and low energy consumption. Combining reaction and separation in an oxygen-permeable membrane reactor significantly simplifies the technological scheme and reduces the process energy consumption. Recently, materials design and mechanism investigations have provided insight into the microstructural and interfacial effects. The microstructures of the membrane surfaces and bulk are closely related to the interfacial oxygen exchange kinetics and bulk diffusion kinetics. Therefore, the permeability and stability of oxygen-permeable membranes with a single-phase structure and a dual-phase structure can be adjusted through their microstructural and interfacial designs. Here, recent advances in the development of oxygen permeation models that provide a deep understanding of the microstructural and interfacial effects, and strategies to simultaneously improve the permeability and stability through microstructural and interfacial design are discussed in detail. Then, based on the developed high-performance membranes, highly effective membrane reactors for process intensification and new technology developments are highlighted. The new membrane reactors will trigger innovations in natural gas conversion, ammonia synthesis, and hydrogen-related clean energy technologies. Future opportunities and challenges in the development of oxygen-permeable membranes for oxygen separation and reaction-separation coupling are also explored.

Thermochemically stable ceramic composite membranes based on Bi2O3 for oxygen separation with high permeability

Ceramic oxygen separation membranes can be utilized to reduce CO2 emissions in fossil fuel power generation cycles based on oxy-fuel combustion. State-of-the-art oxygen permeable membranes based on Ba0.5Sr0.5Co0.8Fe0.2O3-δ (BSCF) offer high oxygen permeability but suffer from long-term instability, especially in the presence of CO2. In this work, we present a novel ceramic composite membrane consisting of 60 vol% (Bi0.8Tm0.2)2O3-δ (BTM) and 40 vol% (La0.8Sr0.2)0.99MnO3-δ (LSM), which shows not only comparable oxygen permeability to that of BSCF but also outstanding long-term stability. At 900 °C, oxygen fluxes of 1.01 mL min-1 cm-2 and 1.33 mL min-1 cm-2 were obtained for membranes with thicknesses of 1.35 mm and 0.75 mm, respectively. Moreover, significant oxygen fluxes were obtained at temperatures down to 600 °C. A stable operation of the membrane was demonstrated with insignificant changes in the oxygen flux at 750 °C for approx. one month and at 700 °C with 50% CO2 as the sweep gas for more than two weeks.

Mixed Ionic-Electronic Conducting Membranes (MIEC) for Their Application in Membrane Reactors: A Review

Mixed ionic-electronic conducting membranes have seen significant progress over the last 25 years as efficient ways to obtain oxygen separation from air and for their integration in chemical production systems where pure oxygen in small amounts is needed. Perovskite materials are the most employed materials for membrane preparation. However, they have poor phase stability and are prone to poisoning when subjected to CO2 and SO2, which limits their industrial application. To solve this, the so-called dual-phase membranes are attracting greater attention. In this review, recent advances on self-supported and supported oxygen membranes and factors that affect the oxygen permeation and membrane stability are presented. Possible ways for further improvements that can be pursued to increase the oxygen permeation rate are also indicated. Lastly, an overview of the most relevant examples of membrane reactors in which oxygen membranes have been integrated are provided.

Mixed Ionic-Electronic Conduction in NiFe2 O4 -Ce0.8 Gd0.2 O2-δ Nanocomposite Thin Films for Oxygen Separation

NiFe₂ O₄ -Ce_0.8 Gd_0.2 O_2-δ (NFO/CGO) nanocomposite thin films were prepared by simultaneously radio-frequency (RF) magnetron sputtering of both NFO and CGO targets. The aim is the growth of a CO₂ -stable composite layer that combines the electronic and ionic conduction of the separate NFO and the CGO phases for oxygen separation. The effect of the deposition temperature on the microstructure of the film was studied to obtain high-quality composite thin films. The ratio of both phases was changed by applying different power to each ceramic target. The amount of each deposited phase as well as the different oxidation states of the nanocomposite constituents were analyzed by means of X-ray photoelectron spectroscopy (XPS). The transport properties were studied by conductivity measurements as a function of temperature and pO₂ . These analyses enabled (1) selection of the best deposition temperature (400 °C), (2) correlation of the p-type electronic behavior of the NFO phase with the hole hopping between Ni³⁺ -Ni²⁺ , and (3) following the conductivity behavior of the grown composite layer (prevailing ionic or electronic character) attained by varying the amount of each phase. The sputtered layer exhibited high ambipolar conduction and surfaceexchange activity. A 150 nm-thick nanograined thin film was deposited on a 20 μm-thick Ba_0.5 Sr_0.5 Co_0.8 Fe_0.2 O_3-δ asymmetric membrane, resulting in up to 3.8 mL min^-1  cm^-2 O₂ permeation at 1000 °C under CO₂ atmosphere.

B-Site Cation-Ordered Double-Perovskite Oxide as an Outstanding Electrode Material for Supercapacitive Energy Storage Based on the Anion Intercalation Mechanism

Perovskite oxides are highly promising electrodes for oxygen-ion-intercalation-type supercapacitors owing to their high oxygen vacancy concentration, oxygen diffusion rate, and tap density. Based on the anion intercalation mechanism, the capacitance is contributed by surface redox reactions and oxygen ion intercalation in the bulk materials. A high concentration of oxygen vacancies is needed because it is the main charge carrier. In this study, we propose a B-site cation-ordered Ba₂Bi_0.1Sc_0.2Co_1.7O_6-δ as an electrode material with an extremely high oxygen vacancy concentration and oxygen diffusion rate. A maximum capacitance of 1050 F g^-1 was achieved, and a high capacitance of 780 F g^-1 was maintained even after 3000 charge-discharge cycles at a current density of 1 A g^-1 with an aqueous alkaline solution (6 M KOH) electrolyte, indicating an excellent cycling stability. In addition, the specific volumetric capacitance of Ba₂Bi_0.1Sc_0.2Co_1.7O_6-δ reaches up to 2549.4 F cm^-3 based on the dense construction and high tap density (3.2 g cm^-3). In addition, an asymmetric supercapacitor was constructed using activated carbon as a negative electrode, and it displayed the highest specific energy density of 70 Wh kg^-1 at the power density of 787 W kg^-1 in this study.

Designing CO2-resistant oxygen-selective mixed ionic-electronic conducting membranes: guidelines, recent advances, and forward directions

CO₂ resistance is an enabling property for the wide-scale implementation of oxygen-selective mixed ionic-electronic conducting (MIEC) membranes in clean energy technologies, i.e., oxyfuel combustion, clean coal energy delivery, and catalytic membrane reactors for greener chemical synthesis. The significant rise in the number of studies over the past decade and the major progress in CO₂-resistant MIEC materials warrant systematic guidelines on this topic. To this end, this review features the pertaining aspects in addition to the recent status and advances of the two most promising membrane materials, perovskite and fluorite-based dual-phase materials. We explain how to quantify and design CO₂ resistant membranes using the Lewis acid-base reaction concept and thermodynamics perspective and highlight the relevant characterization techniques. For perovskite materials, a trade-off generally exists between CO₂ resistance and O₂ permeability. Fluorite materials, despite their inherent CO₂ resistance, typically have low O₂ permeability but this can be improved via different approaches including thin film technology and the recently developed minimum internal electronic short-circuit second phase and external electronic short-circuit decoration. We then elaborate the two main future directions that are centralized around the development of new oxide compositions capable of featuring simultaneously high CO₂ resistance and O₂ permeability and the exploitation of phase reactions to create a new conductive phase along the grain boundaries of dual-phase materials. The final part of the review discusses various complimentary characterization techniques and the relevant studies that can provide insights into the degradation mechanism of oxide-based materials upon exposure to CO₂.