Integrated Heat Recovery System Based on Mixed Ionic-Electronic Conducting Membrane for Improved Solid Oxide Co-Electrolyzer Performance

The current state of mixed ionic-electronic conducting ceramic membrane technology presents significant advancements with potential applications in various fields including solid oxide electrolyzers, fuel cells, hydrogen production, CO2 reduction, and membrane reactors for chemical production and oxygen separation. Particularly in oxygen separation applications, optimal conditions closely align with the conditions of oxygen-rich air streams emitted from the anode of solid oxide co-electrolyzers. This paper describes and analyzes a novel integrated heat recovery system based on mixed ionic-electronic conducting membranes. The system operates in two stages: firstly, oxygen is separated from the anode output stream using mixed ionic-electronic conducting membranes aided by a vacuum system, followed by the heat recovery process. Upon oxygen separation, the swept gas stream is recirculated at temperatures near thermoneutral conditions, resulting in performance improvements at both cell and system levels. Additionally, an oxygen stream is generated for various applications. An Aspen HYSYS® model has been developed to calculate heat and material balances, demonstrating the efficiency enhancements of the proposed system configuration.

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.

Direct Conversion of Methane to C2 Hydrocarbons in Solid-State Membrane Reactors at High Temperatures

Direct conversion of methane to C₂ compounds by oxidative and nonoxidative coupling reactions has been intensively studied in the past four decades; however, because these reactions have intrinsic severe thermodynamic constraints, they have not become viable industrially. Recently, with the increasing availability of inexpensive "green electrons" coming from renewable sources, electrochemical technologies are gaining momentum for reactions that have been challenging for more conventional catalysis. Using solid-state membranes to control the reacting species and separate products in a single step is a crucial advantage. Devices using ionic or mixed ionic-electronic conductors can be explored for methane coupling reactions with great potential to increase selectivity. Although these technologies are still in the early scaling stages, they offer a sustainable path for the utilization of methane and benefit from the advances in both solid oxide fuel cells and electrolyzers. This review identifies promising developments for solid-state methane conversion reactors by assessing multifunctional layers with microstructural control; combining solid electrolytes (proton and oxygen ion conductors) with active and selective electrodes/catalysts; applying more efficient reactor designs; understanding the reaction/degradation mechanisms; defining standards for performance evaluation; and carrying techno-economic analysis.

Hydrogen-Permeable Tubular Membrane Reactor: Promoting Conversion and Product Selectivity for Non-Oxidative Activation of Methane over an Fe©SiO2 Catalyst

Non-oxidative methane conversion over Fe©SiO₂ catalyst was studied for the first time in a hydrogen (H₂ ) permeable tubular membrane reactor. The membrane reactor is composed of a mixed ionic-electronic SrCe_0.7 Zr_0.2 Eu_0.1 O_3-δ thin film (≈20 μm) supported on the outer surface of a one-end capped porous SrCe_0.8 Zr_0.2 O_3-δ tube. Significant improvement in CH₄ conversion was achieved upon H₂ removal from the membrane reactor compared to that in a fixed-bed reactor. The Fe©SiO₂ catalyst in the H₂ permeable membrane reactor demonstrated a stable ≈30 % C₂₊ single-pass yield, with up to 30 % CH₄ conversion and 99 % selectivity to C₂ (ethylene and acetylene) and aromatic (benzene and naphthalene) products, at the tested conditions. The selectivity towards C₂ or aromatics was manipulated purposely by adding H₂ into or removing H₂ from the membrane reactor feed and permeate gas streams.

Auto-thermal reforming using mixed ion-electronic conducting ceramic membranes for a small-scale H₂ production plant

The integration of mixed ionic electronic conducting (MIEC) membranes for air separation in a small-to-medium scale unit for H2 production (in the range of 650-850 Nm3/h) via auto-thermal reforming of methane has been investigated in the present study. Membranes based on mixed ionic electronic conducting oxides such as Ba0.5Sr0.5Co0.8Fe0.2O3-δ (BSCF) give sufficiently high oxygen fluxes at temperatures above 800 °C with high purity (higher than 99%). Experimental results of membrane permeation tests are presented and used for the reactor design with a detailed reactor model. The assessment of the H2 plant has been carried out for different operating conditions and reactor geometry and an energy analysis has been carried out with the flowsheeting software Aspen Plus, including also the turbomachines required for a proper thermal integration. A micro-gas turbine is integrated in the system in order to supply part of the electricity required in the system. The analysis of the system shows that the reforming efficiency is in the range of 62%-70% in the case where the temperature at the auto-thermal reforming membrane reactor (ATR-MR) is equal to 900 °C. When the electric consumption and the thermal export are included the efficiency of the plant approaches 74%-78%. The design of the reactor has been carried out using a reactor model linked to the Aspen flowsheet and the results show that with a larger reactor volume the performance of the system can be improved, especially because of the reduced electric consumption. From this analysis it has been found that for a production of about 790 Nm3/h pure H2, a reactor with a diameter of 1 m and length of 1.8 m with about 1500 membranes of 2 cm diameter is required.