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

Consistent interpretation of isotope and chemical oxygen exchange relaxation kinetics in SrFe0.85Mo0.15O3-δ ferrite

This paper is devoted to the study of phase composition and kinetic and thermodynamic characteristics of Mo-doped strontium ferrite SrFe0.85Mo0.15O3-δ (SFM15) under oxygen-conducting membrane working conditions. Single-phase SFM15 with a cubic Pm3̄m structure was synthesized using a ceramic method. It was shown that the molybdenum introduction stabilizes the perovskite cubic structure over a wide range of oxygen pressures and temperatures, preventing the bulk phase transition at high temperatures. Oxygen exchange constants, diffusion coefficients and activation energy of oxygen exchange were obtained using oxygen relaxation and isotopic exchange techniques, and the obtained values are consistent with known literature data. It was shown that the surface reaction rates obtained using chemical and tracer relaxation methods are quantitatively comparable with each other, despite significantly different experimental conditions. This result not only confirms the reliability of the data obtained by independent methods, but also allows one to expand the area of physical conditions for studying the kinetics of oxygen transfer where another method has technical or methodological limitations.

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.

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.

Hydrogen-Tolerant La0.6Ca0.4Co0.2Fe0.8O3-d Oxygen Transport Membranes from Ultrasonic Spray Synthesis for Plasma-Assisted CO2 Conversion

La0.6Ca0.4Co1-xFexO3-d in its various compositions has proven to be an excellent CO2-resistant oxygen transport membrane that can be used in plasma-assisted CO2 conversion. With the goal of incorporating green hydrogen into the CO2 conversion process, this work takes a step further by investigating the compatibility of La0.6Ca0.4Co1-xFexO3-d membranes with hydrogen fed into the plasma. This will enable plasma-assisted conversion of the carbon monoxide produced in the CO2 reduction process into green fuels, like methanol. This requires the La0.6Ca0.4Co1-xFexO3-d membranes to be tolerant towards reducing conditions of hydrogen. The hydrogen tolerance of La0.6Ca0.4Co1-xFexO3-d (x = 0.8) was studied in detail. A faster and resource-efficient route based on ultrasonic spray synthesis was developed to synthesise the La0.6Ca0.4Co0.2Fe0.8O3-d membranes. The La0.6Ca0.4Co0.2Fe0.8O3-d membrane developed using ultrasonic spray synthesis showed similar performance in terms of its oxygen permeation when compared with the ones synthesised with conventional techniques, such as co-precipitation, sol-gel, etc., despite using 30% less cobalt.

Sensitivity of Material, Microstructure and Operational Parameters on the Performance of Asymmetric Oxygen Transport Membranes: Guidance from Modeling

Oxygen transport membranes can enable a wide range of efficient energy and industrial applications. One goal of development is to maximize the performance by the improvement of the material, microstructural properties and operational conditions. However, the complexity of the transportation processes taking place in such commonly asymmetric membranes impedes the identification of the parameters to improve them. In this work, we present a sensitivity study that allows identification of these parameters. It is based on a 1D transport model that includes surface exchange, ionic and electronic transport inside the dense membrane, as well as binary diffusion, Knudsen diffusion and viscous flux inside the porous support. A support limitation factor is defined and its dependency on the membrane conductivity is shown. For materials with very high ambipolar conductivity the transport is limited by the porous support (in particular the pore tortuosity), whereas for materials with low ambipolar conductivity the transport is limited by the dense membrane. Moreover, the influence of total pressure and related oxygen partial pressures in the gas phase at the membrane's surfaces was revealed to be significant, which has been neglected so far in permeation test setups reported in the literature. In addition, the accuracy of each parameter's experimental determination is discussed. The model is well-suited to guiding experimentalists in developing high-performance gas separation membranes.

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.

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.

Layered Oxygen-Deficient Double Perovskites as Promising Cathode Materials for Solid Oxide Fuel Cells

Development of new functional materials with improved characteristics for solid oxide fuel cells (SOFCs) and solid oxide electrolysis cells (SOECs) is one of the most important tasks of modern materials science. High electrocatalytic activity in oxygen reduction reactions (ORR), chemical and thermomechanical compatibility with solid electrolytes, as well as stability at elevated temperatures are the most important requirements for cathode materials utilized in SOFCs. Layered oxygen-deficient double perovskites possess the complex of the above-mentioned properties, being one of the most promising cathode materials operating at intermediate temperatures. The present review summarizes the data available in the literature concerning crystal structure, thermal, electrotransport-related, and other functional properties (including electrochemical performance in ORR) of these materials. The main emphasis is placed on the state-of-art approaches to improving the functional characteristics of these complex oxides.

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.

Catalytic ceramic oxygen ionic conducting membrane reactors for ethylene production

Catalytic ceramic oxygen ionic conducting membrane reactors have great potential in the production of high value-added chemicals as they can couple chemical reactions with separation within a single unit, allowing process intensification.

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.

Synthesis and Characterization of 40 wt % Ce0.9Pr0.1O2-δ-60 wt % NdxSr1-xFe0.9Cu0.1O3-δ Dual-Phase Membranes for Efficient Oxygen Separation

Dense, H₂- and CO₂-resistant, oxygen-permeable 40 wt % Ce_0.9Pr_0.1O_2–δ–60 wt % Nd_xSr_1−xFe_0.9Cu_0.1O_3−δdual-phase membranes were prepared in a one-pot process. These Nd-containing dual-phase membranes have up to 60% lower material costs than many classically used dual-phase materials. The Ce_0.9Pr_0.1O_2−δ–Nd_0.5Sr_0.5Fe_0.9Cu_0.1O_3−δ sample demonstrates outstanding activity and a regenerative ability in the presence of different atmospheres, especially in a reducing atmosphere and pure CO₂ atmosphere in comparison with all investigated samples. The oxygen permeation fluxes across a Ce_0.9Pr_0.1O_2−δ–Nd_0.5Sr_0.5Fe_0.9Cu_0.1O_3−δ membrane reached up to 1.02 mL min⁻¹ cm⁻² and 0.63 mL min⁻¹ cm⁻² under an air/He and air/CO₂ gradient at T = 1223 K, respectively. In addition, a Ce_0.9Pr_0.1O_2–δ–Nd_0.5Sr_0.5Fe_0.9Cu_0.1O_3–δ membrane (0.65 mm thickness) shows excellent long-term self-healing stability for 125 h. The repeated membrane fabrication delivered oxygen permeation fluxes had a deviation of less than 5%. These results indicate that this highly renewable dual-phase membrane is a potential candidate for long lifetime, high temperature gas separation applications and coupled reaction–separation processes.

Experimental Investigation of the Oxidative Coupling of Methane in a Porous Membrane Reactor: Relevance of Back-Permeation

Novel reactor configurations for the oxidative coupling of methane (OCM), and in particular membrane reactors, contribute toward reaching the yield required to make the process competitive at the industrial scale. Therefore, in this work, the conventional OCM packed bed reactor using a Mn-Na₂WO₄/SiO₂ catalyst was experimentally compared with a membrane reactor, in which a symmetric MgO porous membrane was integrated. The beneficial effects of distributive feeding of oxygen along the membrane, which is the main advantage of the porous membrane reactor, were demonstrated, although no significant differences in terms of performance were observed because of the adverse effects of back-permeation prevailing in the experiments. A sensitivity analysis carried out on the effective diffusion coefficient also indicated the necessity of properly tuning the membrane properties to achieve the expected promising results, highlighting how this tuning could be addressed.

Oxidative Coupling of Methane in Membrane Reactors; A Techno-Economic Assessment

Oxidative coupling of methane (OCM) is a process to directly convert methane into ethylene. However, its ethylene yield is limited in conventional reactors by the nature of the reaction system. In this work, the integration of different membranes to increase the overall performance of the large-scale oxidative coupling of methane process has been investigated from a techno-economic point of view. A 1D membrane reactor model has been developed, and the results show that the OCM reactor yield is significantly improved when integrating either porous or dense membranes in packed bed reactors. These higher yields have a positive impact on the economics and performance of the downstream separation, resulting in a cost of ethylene production of 595–625 €/tonC2H4 depending on the type of membranes employed, 25–30% lower than the benchmark technology based on oil as feedstock (naphtha steam cracking). Despite the use of a cryogenic separation unit, the porous membranes configuration shows generally better results than dense ones because of the much larger membrane area required in the dense membranes case. In addition, the CO2 emissions of the OCM studied processes are also much lower than the benchmark technology (total CO2 emissions are reduced by 96% in the dense membranes case and by 88% in the porous membranes case, with respect to naphtha steam cracking), where the high direct CO2 emissions have a major impact on the process. However, the scalability and the issues associated with it seem to be the main constraints to the industrial application of the process, since experimental studies of these membrane reactor technologies have been carried out just on a very small scale.

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.

Special Issue on “Membrane Materials, Performance and Processes”

This Special Issue on “Membrane Materials, Performance and Processes” of Processes provides a collection of interdisciplinary work representative of the current development in the fields ofmembrane science and technology [...]