Single- and dual-phase capillary membranes prepared through plastic extrusion method for oxygen permeation

Two capillary membranes, single-phase Ba_0.5Sr_0.5Co_0.8Fe_0.2O_3-δ (BSCF) and dual-phase 75 wt% Ce_0.85Sm_0.15O_1.925 - 25 wt% Sm_0.6Sr_0.4Cr_0.3Fe_0.7O_3-δ (SDC-SSCF), with dense cross section, were successfully prepared through the plastic extrusion method. The dual-phase capillary membrane shows higher strength compared to the BSCF counterpart, while the two capillary membranes exhibit much higher fracture strength than those of hollow fiber membranes. The oxygen permeation fluxes of both membranes increase with the increase of temperature and flow rate of sweep gas at the ambient pressure, and can be greatly improved by applying high pressures to the feed side. The oxygen permeation flux of BSCF capillary membrane is up to 19.5 mL cm^?2 min^?1 when 0.5 MPa air was applied to the feed side at 900 °C, which is one order of magnitude higher than that of SDC-SSCF capillary membrane. Thus, both capillary membranes have their own advantages and meet applications under different operation conditions.     

BaxSr1-xCoyFe1-yO3-δ (BSCF) mixed ionic-electronic conducting (MIEC) materials for oxygen separation membrane and SOFC applications: Insights into processing,stability, and functional properties

Cubic perovskite Ba_xSr_1-xCo_yFe_1-yO_3-δ (BSCF), with x = 0.5 and y = 0.8, is one of the oxygen permeable mixed ionic-electronic conducting (MIEC) membrane materials having the highest oxygen permeation flux reported. The material has potential for high-temperature electrochemical applications such as oxygen separation membrane and cathode for Solid Oxide Fuel Cells (SOFCs). The material has been highly studied, focusing on the oxygen transport properties, thermochemical expansion, mechanical properties, high temperature creep behavior, chemical sealing, etc. Therefore, a review article that consolidates the existing knowledge is necessary. The available review articles have focused on mechanical properties and applications as cathode for intermediate temperature (IT) SOFCs. Hence, this review article has covered additional information about crystal structure and oxygen non-stoichiometry of BSCF, material synthesis, membrane fabrication, thermomechanical stability, phase stability with respect to temperature and oxygen partial pressure, mechanical properties as well as the performance analysis in terms of oxygen permeation flux and failure analysis. It also emphasizes the potential of BSCF as MIEC membrane material. The content is equally helpful for researchers who are newcomers to the field and have the intention to provide a basic understanding of MIEC membrane materials.     

Co‐firing technology for the preparation of asymmetric oxygen transporting membranes based on BSCF and Zr‐doped BSCF

Asymmetric tubular membranes with a length of 450 mm were prepared in one step by co‐firing of a green support coated by slurry. BSCF (Ba_0.5Sr_0.5Co_0.8Fe_0.2O_3‐δ) and Zr‐doped BSCF3Zr (Ba_0.5Sr_0.5(Co_0.8Fe_0.2)_0.97Zr_0.03O_3‐δ) were used for the separation layer as well as for the porous support, latter one together with PMMA microspheres as a pore forming agent. The gas leakage at room temperature was below 0.003 mL STP/(cm²·min). Oxygen fluxes up to 12 mL STP/(cm²·min) were observed at 900°C in vacuo operation mode. The oxygen flux increased with growing driving force but the slope of the curve flattened at higher driving forces probably caused by limiting surface exchange and pressure losses inside the porous support. The oxygen permeation of asymmetric BSCF tubes was slightly higher compared to BSCF3Zr and exceeded the oxygen flux of a monolithic BSCF membrane by a factor of 4 at comparable operation conditions. © 2013 American Institute of Chemical Engineers AIChE J, 60: 15–21, 2014     

Performance control of dead-end tubular membranes fabricated with a modified phase inversion casting method

A modified phase inversion casting method is employed for the formation of dead-end tubular membrane shape in a single step. Ce_0.9Gd_0.1O_1.95-δ (CGO)-Ba_0.5Sr_0.5Co_0.8Fe_0.2O_3-δ (BSCF) composites are applied as the membrane material. Performance of the membrane is optimised by adjusting the processing conditions in the fabrication process. Long finger-like channels, which were found to promote oxygen permeation flux without decrease of the membrane mechanical strength, were obtained in the dead-end tubes by adjusting the ceramic loadings of the casting slurries. Slurries with lower viscosity provided reduced resistance for the channel growth during the phase inversion in water. The performance of the dual-phase membranes with varied CGO:BSCF ratios were compared. The membranes containing more BSCF show higher oxygen permeation fluxes with helium as sweep gas. It was also verified that CGO content played an important role in enhancing the mechanical strength of the CGO-BSCF membranes.     

Preparation and Oxygen Permeation Properties of BaCrOx Coated Ba0.5Sr0.5Co0.8Fe0.2O3- Tubular Membrane

Barium-chromium oxide (BaCrO_x) coated Ba_0.5Sr_0.5Co_0.8Fe_0.2O_3-δ (BSCF) tubular membranes were successfully prepared and evaluated for oxygen separation applications under high pressure–temperature conditions. The oxygen permeation flux was measured in accordance with the temperature, air pressure, and retentate flow rate, ranging from 750–950°C, 3–9 atm, and 200–1000 mL/min, respectively. The permeation testing on the BaCrO_x coated BSCF tubular membranes showed that the oxygen flux increased as the temperature, pressure, and retentate flow rate increased. The oxygen permeation flux was 5.7 mL/(min cm²) with temperature, pressure, and retentate flow rate of 900°C, 9 atm, and 1000 mL/min, respectively. The temperature dependence of the oxygen permeation process is further investigated, and the Arrhenius pre-exponential factor, as well as the apparent activation energy, is determined.     

Oxygen transport kinetics of MIEC membranes coated with different catalysts

Oxygen permeation through mixed ionic‐electronic conducting membrane may be controlled by oxygen bulk diffusion and/or oxygen interfacial exchange kinetics. In this article, we chose BaCe_0.05Fe_0.95O_3‐δ (BCF) as a representative to study the oxygen transport resistances of the membrane coated with different porous catalysts, including BCF itself, Ba_0.5Sr_0.5Co_0.8Fe_0.2O_3‐δ (BSCF) and Sm_0.5Sr_0.5CoO_3‐δ (SSC). The oxygen transport resistances of bulk, gas‐solid interfaces of feed‐side and sweep‐side of the catalyst‐coated membranes can be separately obtained through a linear regression of experimental data according to an oxygen permeation model. The three resistances of the membrane coated with BCF catalyst are smaller than those of the membrane coated with BSCF and SSC catalysts, although BSCF catalyst itself has the fastest bulk diffusion and interfacial exchange kinetics. The catalytic activities of BSCF and SSC catalysts on BCF membranes are impacted by the transport kinetics of catalysts, microstructure of catalyst layers, and cationic inter‐diffusion between the membrane and catalysts. © 2016 American Institute of Chemical Engineers AIChE J, 62: 2803–2812, 2016     

Further performance improvement of Ba0.5Sr0.5Co0.8Fe0.2O3−δ perovskite membranes for air separation

Perovskite Ba_0.5Sr_0.5Co_0.8Fe_0.2O_3−δ (BSCF) is a promising mixed conducting ceramic membrane material for air separation. In this work, BSCF powder was synthesized by a modified Pechini sol–gel technique at relatively lower temperature. The O₂ permeation through a series of BSCF membranes has been tested at different temperatures and various O₂ partial pressure gradients. Theoretical investigation indicated that bulk diffusion and the O₂ exchange reactions on membrane surfaces jointly controlled the O₂ permeation through BSCF membranes with thickness of between 1.1 and 0.75 mm. To further improve the O₂ fluxes, effective efforts are made on membrane thickness reduction and surface modification by spraying porous BSCF layers on both surfaces. When the membrane thickness was reduced from 0.75 to 0.40 mm, the O₂ fluxes were increased by 20–60% depending on the operating conditions. The surface modification further improved the O₂ flux by another 20–40%. The high O₂ fluxes achieved in this work are quite encouraging with a maximum value reaching 6.0 mL min⁻¹ cm⁻² at 900 °C.     

Effect of microstructure on oxygen permeation of Ba0.5Sr0.5Co0.8Fe0.2O3−δ and SrCo0.8Fe0.2O3−δ membranes

The effect of grain size on oxygen permeation properties of Ba_0.5Sr_0.5Co_0.8Fe_0.2O_3?δ (BSCF) and SrCo_0.8Fe_0.2O_3?δ (SCF) membranes was investigated by variation of the dwell time. The membrane microstructure was examined by field-emission scanning microscopy (FE-SEM) and then evaluated using a statistical approach. With longer dwell times the grain growth was stimulated and leaded to grains with a narrower size distribution. The grains of SCF (average size from 11.3 to 19.9 μm) were found to be smaller than those of BSCF (average size from 13.9 to 41.3 μm). The oxygen permeation flux of BSCF membranes was found to be independent of grain size in the range from 24 to 42 μm. However, membranes with smaller grains (13.9 μm) show a decreased oxygen permeation flux. For the SCF membranes a decrease in permeation flux with larger grains was observed for average grain sizes between 11.3 and 19.9 μm. By transmission electron microscopy (TEM) formation of an oxygen ordered SrCo_0.8Fe_0.2O_2.5 brownmillerite by-phase could be observed at the oxygen-depleted sweep side of the membrane.     

Yttrium doping of Ba0.5Sr0.5Co0.8Fe0.2O3-δ part II: Influence on oxygen transport and phase stability

Ba_0.5Sr_0.5Co_0.8Fe_0.2O_3-δ (BSCF) in its cubic perovskite phase has attracted much interest for potential use as oxygen transport membrane (OTM) due to its very high oxygen permeability at high temperatures. However, performance degradation due to a sluggish phase decomposition occurs when BSCF is operated below 840?°C. Partial B-site substitution of the transition metal cations in BSCF by larger and redox-stable cations has emerged as a potential strategy to improve the structural stability of cubic BSCF. In this study, the influence of yttrium doping (0…10?mol-%) on oxygen transport properties and stability of the cubic BSCF phase is assessed by in situ electrical conductivity relaxation (ECR) and electrical conductivity measurements during long-term thermal annealing both at 700?°C and 800?°C. Detailed phase analysis is performed by scanning electron microscopy (SEM) after long-term annealing of the samples in air at different temperatures.     

Experimental investigation and mathematical modeling of oxygen permeation through dense Ba0.5Sr0.5Co0.8Fe0.2O3−δ (BSCF) perovskite-type ceramic membranes

Ba_0.5Sr_0.5Co_0.8Fe_0.2O_3?δ (BSCF) perovskite powder was synthesized via EDTA/citrate complexation method. BSCF membranes were formed by pressing powder at 400 MPa and sintering at 1100 °C for 10 h. XRD patterns showed that a high pure powder with cubic structure was obtained. SEM micrographs revealed that the membranes are dense with large grains. Effects of temperature, feed and permeate side oxygen partial pressures, flow rates and membrane thickness on oxygen permeation flux were studied experimentally. A Nernst–Planck based mathematical model, including surface exchange kinetics and bulk diffusion, was developed to predict oxygen permeation flux. Considering non-elementary surface reactions and introducing system hydrodynamics into the model resulted in an excellent agreement (RMSD = 0.0617, AAD = 0.0487 and R² = 0.985) between predicted and measured fluxes. The results showed that oxygen permeation flux increases with temperature, feed side oxygen partial pressure and flow rates, however decreases with permeate side oxygen partial pressure and membrane thickness. Contribution of feed side surface exchange reactions, bulk diffusion and permeate side surface exchange reactions resistances in the total resistance are in the range of 8–32%, 10–81% and 11–59%, respectively. Permeation rate-limiting step was determined using the membrane dimensionless characteristic thickness.     

Fabrication of BSCF-based mixed ionic-electronic conducting membrane by electrophoretic deposition for oxygen separation application

Ba_0.5Sr_0.5Co_0.8Fe_0.2O_3-δ (BSCF), which exhibits a high mixed oxide ionic-electronic conduction, was used for the fabrication of an oxygen separation membrane. An asymmetric structure, which was a thin and dense BSCF membrane layer supported on a porous BSCF substrate, was fabricated by the electrophoretic deposition method (EPD). Porous BSCF supports were prepared by the uniaxial pressing method using a powder mixture with BSCF and starch as the pore-forming agent (0–50 wt.%). The sintering behaviors of the porous support and the thin layer were separately characterized by dilatometry to determine the co-fired temperature at which cracking did not occur. A crack-free and thin dense membrane layer, which had about a 15 μm thickness and >95% relative density, was obtained after optimizing the processes of EPD and sintering. The dense/porous interface was well-bonded and the oxygen permeation flux was 2.5 ml (STP) min⁻¹ cm^-2 at 850 °C.     

Thermochemical expansion of mixed-conducting (Ba,Sr)Co0.8Fe0.2O3−δ ceramics

The thermal and chemical expansion of Ba_0.5Sr_0.5Co_0.8Fe_0.2O_3−δ (BSCF) and SrCo_0.8Fe_0.2O_3−δ (SCF) mixed ionic-electronic conductors were studied in combination with oxygen nonstoichiometry (δ) at 298–1223 K and p(O₂) = 10⁻⁴ to 1.00 atm. In order to minimize the effects of phase separation or oxygen-vacancy ordering processes, the data were collected in dynamic cooling mode using dense ceramic samples. The procedure was justified by a very fast equilibration at given p(O₂) in high-temperature range demonstrated for ceramics samples with different specific surface area. The difference in nonstoichiometry of BSCF and SCF at temperatures ≥973 K was found to be ≤0.03 oxygen atoms per formula unit. BSCF demonstrates favorably smaller chemical expansion compared to SCF and many other mixed conductors, originating from smaller δ variations and larger unit cell less sensitive to temperature and nonstoichiometry changes. Excessive thermochemical expansion impedes however the use of BSCF in single-phase fuel cell cathodes and planar mixed-conducting membranes.     

Assessment of Ba0.5Sr0.5Co1−yFeyO3−δ (y = 0.0-1.0) for prospective application as cathode for IT-SOFCs or oxygen permeating membrane

The influence of iron doping level in Ba_0.5Sr_0.5Co_1−yFe_yO_3−δ (y = 0.0-1.0) (BSCF) oxides on their phase structure, oxygen nonstoichiometry, electrical conductivity, performance as symmetrical cell electrode and oxygen permeating membranes was systematically investigated. A cubic perovskite structure was observed for all the compositions with the presence of iron. The increase of iron doping level resulted in the decrease of the lattice constant, room-temperature oxygen nonstoichiometry, total electrical conductivity, and the increase of area specific resistance (ASR) as cathode with samaria doped ceria electrolyte. However, promising cathode performance with an ASR as low as 0.613 Ω cm² was still obtained at 600 °C for Ba_0.5Sr_0.5FeO_3−δ (BSF). The ceramic membranes composing of BSCF with various iron doping level are all oxygen semi-permeable at elevated temperatures. The increase of iron doping level resulted in the decrease of oxygen permeation flux from JO₂ = 2.28 μmol cm⁻² s⁻¹ (STP) for Ba_0.5Sr_0.5Co_0.8Fe_0.2O_3−δ (BSCF5582) to ∼0.45 μmol cm⁻² s⁻¹ (STP) at 900 °C for BSF (y = 1.0) with the same membrane thickness of 1.1 mm, alongside with the change of the rate-determination step from the oxygen surface exchange to the slow oxygen bulk diffusion. The formation of composite oxide with a proper electronic conducting phase and the thin film technology are important for their prospective application as cathode in IT-SOFCs and oxygen permeating membrane, respectively.     

O2 Separation Using MIEC Membranes and Steam Circulation Process

MIEC (mixed ionic-electronic conductors) membranes are used to separate oxygen from air. In this article the functionality of these membranes with steam to produce high-purity oxygen is presented. Compared to other sweep gases, the utilization of steam with MIEC enables the decentral production of oxygen using mainly thermal energy. This is especially advantageous for small and medium-sized consumers; whereby they can produce their demand for oxygen through the recovery of waste heat at high temperatures and without extra transport costs. Therefore, a test rig was developed to investigate the MIEC membrane tubes made of Ba_0.5Sr_0.5Co_0.8Fe_0.2O_3-δ (BSCF) at different temperatures. The results of the experiments establish a proof of concept for this process.     

Yttrium doping of Ba0.5Sr0.5Co0.8Fe0.2O3-δ part I: Influence on oxygen permeation,electrical properties,reductive stability,and lattice parameters

Ba_0.5Sr_0.5Co_0.8Fe_0.2O_3-δ (BSCF) exhibits a very high oxygen permeability in its cubic perovskite phase, making it a promising candidate for high-temperature energy-related applications such as oxygen-transport membranes. It suffers, however, from a pronounced phase instability at application-relevant temperatures below 840?°C which is presumed to result from a valence change of B-site cobalt. In an attempt to stabilize the cubic BSCF phase, monovalent Y³⁺ was doped in small concentrations (1–10?mol-% yttrium) onto its B-site. The influence of this doping on the physico-chemical properties (electrical conductivity, reductive stability, lattice constant), on the sintering behavior, and on the oxygen permeation of BSCF has been systematically investigated. Despite a slightly adverse effect to permeability (decrease in oxygen permeation by about 20–30%), a doping concentration of 10?mol-% Y is found to completely suppress secondary-phase formation and, hence, stabilize the cubic BSCF system at 800?°C. These findings are extremely promising with regard to a long-term operation of BSCF in atmospheres free of acidic impurity gases.     

Fabrication of BSCF-based mixed oxide ionic-electronic conducting multi-layered membrane by sequential electrophoretic deposition process

The Ba_0.5Sr_0.5Co_0.8Fe_0.2O_3-δ (BSCF)-based multi-layered oxygen separation membrane was fabricated by the sequential electrophoretic deposition (EPD) process. A thin porous/dense bi-layer of BSCF was formed on a thick porous support of BSCF. The porous support prepared by a sacrificial template method using BSCF powder mixed with wheat starch (30 wt%) as a pore-forming agent, followed by uniaxial pressing and low-temperature sintering, was directly used as an EPD electrode. A thin BSCF layer was first formed on the porous support, and then a thin BSCF + PMMA (polymethyl methacrylate) layer was sequentially formed on the thin BSCF layer using a bimodal suspension of BSCF and PMMA. A 30-μm thin porous/dense bi-layer of BSCF of which the total thickness was obtained by optimizing the processes of EPD and subsequent co-sintering. The oxygen separation performance of 3.7 ml (STP) min^?1 cm^?2 at 860 °C was achieved for the BSCF-based multi-layered oxygen separation membrane.     

The effect of an oxygen partial pressure gradient on the mechanical behavior of perovskite membrane materials

In application of perovskite as oxygen conducting materials the membrane is operated at elevated temperatures under an oxygen gradient. The effect of the partial pressure difference on the mechanical properties is reported in the current work. Ba_0.5Sr_0.5Co_0.8Fe_0.2O_3−δ (BSCF) and La_0.58Sr_0.4Co_0.2Fe_0.8O_3−δ (LSCF) samples were annealed under an oxygen gradient. The mechanical properties of cross-sections were characterized using indentation testing. Chemical strains for BSCF and LSCF were too small to detect them after cooling to RT by XRD; however, the results suggest that the indentation crack length is affected by chemical strains for LSCF, but not for BSCF. An anisotropy of the indentation crack length and corresponding apparent fracture toughness is related with the interaction of domain switching and residual strain that is probably also associated with the observation that vacuum (10⁻⁵ mbar) annealed LSCF showed surface cracking on heating in air, whereas for BSCF such fracture features were not observed.     

Strength degradation and failure limits of dense and porous ceramic membrane materials

Thin dense membrane layers, mechanically supported by porous substrates, are considered as the most efficient designs for oxygen supply units used in Oxy-fuel processes and membrane reactors. Based on the favorable permeation properties and chemical stability, several materials were suggested as promising membrane and substrate materials: Ba_0.5Sr_0.5Co_0.8Fe_0.2O_3?δ, La_0.6?xSr_0.4Co_0.2Fe_0.8O_3?δ (x = 0, 0.02) and Ce_0.9Gd_0.1O_1.95?δ. Although membranes operate at elevated temperatures, the ends of tubes in certain three-end concepts remain almost at room temperature. The current work concentrates on the failure potential of these membrane parts, where in a complex device also the highest residual stresses should arise due to differences in thermal expansion. In particular, sensitivity of the materials to subcritical crack growth was assessed since the long-term reliability of the component does not only depend on its initial strength, but also on strength degradation effects. The results were subsequently used as a basis for a strength–probability–time lifetime prediction.     

Oxygen permeation of various archetypes of oxygen membranes based on BSCF

Ba_0.5Sr_0.5Co_0.8Fe_0.2O_3‐δ tubes, capillaries, capillary modules, and asymmetric membranes were prepared and tested for oxygen permeation in a dead‐end vacuum operation mode at temperatures up to 850^°C. The capillary module was built up by reactive air brazing using seven capillaries and a supply tube. Two machined discs were used as an end cap and as a connector plate. The oxygen permeation behaves according to Wagner at small driving forces, but significant negative deviations were observed for asymmetric membranes and single capillaries at higher ones. This is caused by pressure drops at the vacuum side for single capillaries. The highest oxygen flux was revealed for the capillary module with 175.5 mL(STP)/min at a low‐vacuum pressure of 0.042 bar at 850^°C, but the asymmetric membrane showing a little bit higher flux at moderate vacuum pressures above 0.07 bar. © 2012 American Institute of Chemical Engineers AIChE J, 58: 3195–3202, 2012     

The effect of B-site Y substitution on cubic phase stabilization in (Ba0.5Sr0.5)(Co0.8Fe0.2)O3−δ

The cubic phase mixed ionic-electronic conductor (Ba_0.5Sr_0.5)(Co_0.8Fe_0.2)O_3−δ (BSCF) is well-known for its excellent oxygen ion conductivity and high catalytic activity. However, formation of secondary phases impedes oxygen ion transport and consequentially a widespread application of BSCF as oxygen transport membrane. B-cation substitution by 1, 3 and 10 at.% Y was employed in this work for stabilization of the cubic BSCF phase. Secondary phase formation was quantified on bulk and powder samples exposed to temperatures between 640 and 1100°C with annealing time up to 44 days. The phase composition, cation valence states, and chemical composition of all samples were analyzed by high-resolution analytical electron microscopic techniques. Y doping effectively suppresses the formation of Ba_n+1Co_nO_3n+3(Co₈O₈) (n ≥ 2) and Co_xO_y phases which would otherwise act as nucleation centers for the highly undesirable hexagonal BSCF phase. This work validates for 10 at.% Y cation substitution perfect stabilization of the cubic BSCF phase at temperatures ≥800°C, while a negligible small volume fraction of the hexagonal BSCF phase was found at lower temperatures. A newly developed model describes the effect of Y doping on the formation of secondary phases and their effective suppression with increasing Y concentration.