Oxidative coupling of methane in Ba0.5Sr0.5Co0.8Fe0.2O3−δ tubular membrane reactors

A dense membrane tube made of Ba_0.5Sr_0.5Co_0.8Fe_0.2O_3−δ (BSCF) was prepared by plastic extrusion from BSCF oxide synthesized by the complexing EDTA-citrate method. The membrane tube was used in a catalytic membrane reactor for oxidative coupling of methane (OCM) to C₂ without an additional catalyst. At high methane concentration (93%), about 62% C₂ selectivity was obtained, which is higher than that achieved in a conventional reactor using the BSCF as a catalyst. The dependence of the OCM reaction on temperature and methane concentration indicates that the C₂ selectivity in the BSCF membrane reactor is limited by high ion recombination rates. If an active OCM catalyst (La-Sr/CaO) was packed in the membrane tube, C₂ selectivity and CH₄ conversion increased compared to the blank run. The highest C₂ yield in the BSCF membrane reactor in presence of the La-Sr/CaO catalyst was about 15%, similar to that in a packed-bed reactor with the same catalyst under the same conditions. However, the ratio of C₂H₄/C₂H₆ in the membrane reactor was much higher than that in the packed-bed reactor, which is an advantage of the membrane reactor.     

Partial oxidation of methane in Ba0.5Sr0.5Co0.8Fe0.2O3−δ membrane reactor at high pressures

Oxygen permeation fluxes through dense disk-shaped Ba_0.5Sr_0.5Co_0.8Fe_0.2O_3−δ (BSCFO) membranes were investigated as a function of temperature (973–1123 K), pressure (2–10 atm), and membrane thickness (1–2 mm) under an air/helium gradient. A high oxygen permeation flux of 2.01 ml/cm² min was achieved at 1123 K and 10 atm under an air/He oxygen partial pressure gradient. Based on the dependence of the oxygen permeation flux on the oxygen partial pressure difference across the membrane and the membrane thickness, it is assumed that bulk diffusion of oxygen ions was the rate-controlling step in the oxygen transport across the BSCFO membrane disk under an air/He gradient. The partial oxidation of methane (POM) to syngas using LiLaNiO_x/γ-Al₂O₃ as catalyst in a BSCFO membrane reactor was successfully performed at high pressure (5 atm). Ninety-two percent methane conversion, 90% CO selectivity, and 15.5 ml/cm² min oxygen permeation flux were achieved in steady state at a temperature of 1123 K and a pressure of 5 atm. A syngas production rate of 79 ml/cm² min was obtained. Characterization of the membrane surface by SEM and XRD after reaction showed that the surface exposed to the air side preserved the Perovskite structure while the surface exposed to the reaction side was eroded.     

Investigation on the partial oxidation of methane to syngas in a tubular Ba0.5Sr0.5Co0.8Fe0.2O3−δ membrane reactor

A perovskite material of Ba_0.5Sr_0.5Co_0.8Fe_0.2O_3−δ (BSCF), with both electronic and ionic conductivity, was synthesized by a combined citrate–EDTA complexing method. The dense membrane tube made of BSCF was fabricated using the plastic extrusion method. The partial oxidation of methane (POM) to syngas was performed in the tubular BSCF membrane reactor packed with a LiLaNiO/γ–Al₂O₃ catalyst. The reaction performance of the membrane reactor was investigated as functions of temperature, air flow rate in the shell side and methane concentration in the tube side. The mechanism of POM in the membrane reactor was discussed in detail. It was found that in the tubular membrane reactor, combustion reaction of methane with permeated oxygen took place in the reaction zone close to the surface of the membrane, then followed by steam and CO₂ reforming of methane in the middle zone of the tube side. The membrane tube can be operated steadily for 500 h in pure methane with 94% methane conversion and higher than 95% CO selectivity, and higher than 8.0 ml/cm² min oxygen permeation flux.     

Improving the oxygen permeability of Ba0.5Sr0.5Co0.8Fe0.2O3−δ membranes by a surface-coating layer of GdBaCo2O5+δ

A GdBaCo₂O_5+δ layer was coated on the Ba_0.5Sr_0.5Co_0.8Fe_0.2O_3−δ membranes to enhance their oxygen permeability by employing the fast oxygen adsorption/desorption surface-exchange properties of the GdBaCo₂O_5+δ material. The oxygen flux of the coated and uncoated Ba_0.5Sr_0.5Co_0.8Fe_0.2O_3−δ membranes was measured in the temperature range of 600–850 °C. The results reveal that the oxygen-permeation flux of the Ba_0.5Sr_0.5Co_0.8Fe_0.2O_3−δ membranes coated by a GdBaCo₂O_5+δ layer shows significant enhancement. The GdBaCo₂O_5+δ layer coated on the oxygen desorption side (He side) has much effect than that coated on the oxygen adsorption side (air side). At 850 °C, the oxygen flux with a single coating layer on the air side can rise 16%, while a single coating on the helium side will result into a rise of 23%.     

Mechanical characterization of porous Ba0.5Sr0.5Co0.8Fe0.2O3−d

The mechanical stability of porous Ba_0.5Sr_0.5Co_0.8Fe_0.2O_3−d (BSCF) material was investigated using depth-sensitive microindentation and ring-on-ring biaxial bending tests. The porous BSCF was characterized as potential substrate material for the deposition of a dense membrane layer. Indentation tests yielded values for hardness and fracture toughness up to a temperature of 400 °C, while bending tests permitted an assessment of elastic modulus and fracture stress up to 800 °C. In addition the fracture toughness was evaluated up to 800 °C measuring in bending tests the fracture stress of pre-indented specimens. The results proof that the indentation-strength method can be applied for the determination of the fracture toughness of this porous material. In comparison to dense material the values of the mechanical parameters were as expected lower but the temperature dependences of elastic modulus, fracture strength and toughness were similar to those reported for dense BSCF.     

Micro- and macro-indentation behaviour of Ba0.5Sr0.5Co0.8Fe0.2O3−d perovskite

Ba_0.5Sr_0.5Co_0.8Fe_0.2O_3−d (BSCF) is a candidate material for the application as oxygen separation membrane. However, the requisite mechanical reliability needs to be warranted. Indentation tests on dense BSCF yielded data for hardness, stiffness and fracture toughness up to a temperature of 340 °C. Complementary to this, the fracture toughness was also evaluated up to 800 °C based on an indentation-strength method.Up to 200 °C, the values of all characteristic mechanical parameters decreased. At high temperatures they increased. The morphology of the indentation cracks depended on the applied indentation load. This was taken into account while selecting suitable expressions for calculating indentation toughness. The temperature dependence of the normalised fracture toughness as determined by indentation technique and indentation-strength method matched quite well. They revealed a good agreement with the temperature dependence of previously reported normalised fracture stresses. In addition to this, the effect of annealing on the mechanical properties of the material was also studied.     

Mixed reforming of heptane to syngas in the Ba0.5Sr0.5Co0.8Fe0.2O3 membrane reactor

Fuel cells are recognized as the most promising new power generation technology, but hydrogen supply is still a problem. In our previous work, we have developed a LiLaNiO/γ-Al₂O₃ catalyst, which is excellent not only for partial oxidation of hydrocarbons, but also for steam reforming and autothermal reforming. However, the reaction needs pure oxygen or air as oxidant. We have developed a dense oxygen permeable membrane Ba_0.5Sr_0.5Co_0.8Fe_0.2O₃ which has an oxygen permeation flux around 11.5 ml/cm² min at reaction conditions. Therefore, this work is to combine the oxygen permeable membrane with the catalyst LiLaNiO/γ-Al₂O₃ in a membrane reactor for hydrogen production by mixed reforming of heptane. Under optimized reaction conditions, a heptane conversion of 100%, a CO selectivity of 91–93% and a H₂ selectivity of 95–97% have been achieved.     

Effects of preparation methods on the oxygen nonstoichiometry, B-site cation valences and catalytic efficiency of perovskite La0.6Sr0.4Co0.2Fe0.8O3−δ

La_0.6Sr_0.4Co_0.2Fe_0.8O_3−δ (LSCF) powders were synthesized respectively by an EDTA (ethylenediaminetetraacetic acid)–Citrate sol–gel process and a low-temperature auto-combustion process. The samples were characterized by XRD, SEM, BET, TGA and instant temperature analysis. The iodometric titration was used to determine the average valence of Co and Fe ions and the oxygen nonstoichiometry of the prepare powders. The catalytic properties of the synthesized powders were investigated by the hydrogen peroxide catalytic decomposition. Pure-perovskite structure was formed by both synthesis methods. The oxygen nonstoichiometry of the samples prepared by the auto-combustion process is larger than that by the sol–gel process. The catalytic activities of the powders from two synthesis processes also differed largely due to the different oxygen nonstoichiometry, surface area and crystalline sizes.     

Nano-sized Sm0.5Sr0.5CoO3−δ as the cathode for solid oxide fuel cells with proton-conducting electrolytes of BaCe0.8Sm0.2O2.9

Nano-sized Sm_0.5Sr_0.5CoO_3−δ (SSC) was fabricated onto the inner face of porous BaCe_0.8Sm_0.2O_2.9 (BCS) backbone by ion impregnation technique to form a composite cathode for solid oxide fuel cells (SOFCs) with BCS, a proton conductor, as electrolyte. The electro-performance of the composite cathodes was investigated as function of fabricating conditions, and the lowest polarization resistance, about 0.21 Ω cm² at 600 °C, was achieved with BCS backbone sintered at 1100 °C, SSC layer fired at 800 °C, and SSC loading of 55 wt.%. Impedance spectra of the composite cathodes consisted of two depressed arcs with peak frequency of 1 kHz and 30 Hz, respectively, which might correspond to the migration of proton and the dissociative adsorption and diffusion of oxygen, respectively. There was an additional arc peaking at 1 Hz in the Nyquist plots of a single cell, which should correspond to the anode reactions. With electrolyte about 70 μm in thickness, the simulated anode, cathode and bulk resistances of cells were 0.021, 0.055 and 0.68 Ω cm² at 700 °C, relatively, and the maximum power density was 307 mW cm⁻² at 700 °C.     

Layered NdBaCo2−xNixO5+δ perovskite oxides as cathodes for intermediate temperature solid oxide fuel cells

The effect of Ni substitution on the crystal chemistry, thermal and electrochemical properties, and catalytic activity for oxygen reduction reaction of the layered NdBaCo_2−xNi_xO_5+δ perovskite oxides has been investigated for 0 ≤ x ≤ 0.6. The oxygen content (5 + δ) and oxidation state of the (Co, Ni) ions in the air-synthesized NdBaCo_2−xNi_xO_5+δ samples decrease with increasing Ni content, accompanied by a structural transition from tetragonal (0 ≤ x ≤ 0.4) to orthorhombic (x = 0.6). Similarly, the thermal expansion coefficient (TEC) and electrical conductivity also decrease with increasing Ni content. The x = 0.2 and 0.4 samples exhibit slightly improved performance as cathodes in single cell solid oxide fuel cell (SOFC) compared to the x = 0 sample, which is in accordance with the ac-impedance data. Among the samples studied, the x = 0.4 sample exhibits a combination of low thermal expansion and high catalytic activity for the oxygen reduction reaction in SOFC.     

Reaction and oxygen permeation studies in Sm0.4Ba0.6Fe0.8Co0.2O3 − δ membrane reactor for partial oxidation of methane to syngas

A disk-type Sm_0.4Ba_0.6Co_0.2Fe_0.8O_3 − δ perovskite-type mixed-conducting membrane was applied to a membrane reactor for the partial oxidation of methane to syngas (CO + H₂). The reaction was carried out using Rh (1 wt%)/MgO catalyst by feeding CH₄ diluted with Ar. While CH₄ conversion increased and CO selectivity slightly decreased with increasing temperature, a high level of CH₄ conversion (90%) and a high selectivity to CO (98%) were observed at 1173 K. The oxygen flux was increased under the conditions for the catalytic partial oxidation of CH₄ compared with that measured when Ar was fed to the permeation side. We investigated the reaction pathways in the membrane reactor using different membrane reactor configurations and different kinds of gas. In the membrane reactor without the catalyst, the oxygen flux was not improved even when CH₄ was fed to the permeation side, whereas the oxygen flux was enhanced when CO or H₂ was fed. It is implied that the oxidation of CO and H₂ with the surface oxygen on the permeation side improves the oxygen flux through the membrane, and that CO₂ and H₂O react with CH₄ by reforming reactions to form syngas.     

Kinetic study on the role of an LSGMC5 interlayer in improving the performance of Sm0.5Sr0.5CoO3-La0.8Sr0.2Ga0.8Mg0.15Co0.05O3 (LSGMC5)/LSGMC5 interface

The kinetics of oxygen reduction over various Sm_0.5Sr_0.5CoO₃(SSC)-La_0.8Sr_0.2Ga_0.8Mg_0.15Co_0.05O₃(LSGMC5)/LSGMC5 (interlayer)/LSGMC5 (electrolyte) assemblies were studied, which were essential to find the role of an interlayer in improving the performance of an electrode/electrolyte interface. Two major arcs were identified in the impedance spectra at near equilibrium conditions. The reciprocal of the electrode resistance corresponding to the high frequency arc showed a PO₂ dependency about 0.5 at 1073 K and decreased to one-fourth at 873 K, suggesting that the rate-determining step (rds) changed from the dissociative adsorption of oxygen or diffusion of adsorbed oxygen atoms to charge transfer. The reciprocal of the electrode resistance corresponding to the low frequency arc showed a PO₂ dependency about 1, suggesting an rds involving the gas diffusion of oxygen. DC polarization curves of various assemblies agreed well with the Butler-Volmer equation. Both the cathodic and anodic charge transfer coefficients were about 1, and the PO₂ dependencies of the exchange current densities were about 0.25, especially at low temperatures. The characteristics under polarization corresponded to a charge transfer process. The introduction of an LSGMC5 interlayer between the SSC-LSGMC5 electrode and LSGMC5 electrolyte did not change the reaction mechanism, and the role of the interlayer was to increase the number of active sites for oxygen reduction.     

Electrochemical behavior of Ln0.6Sr0.4Co0.2Fe0.8O3−δ (Ln=Ce, Gd, Sm, Dy) materials used as cathode of IT-SOFC

The perovskite-type compounds Ln_0.6Sr_0.4Co_0.2Fe_0.8O_3−δ (Ln=Ce, Sm, Gd, Dy) used as the cathodes of intermediate temperature solid oxide fuel cell (IT-SOFC) were studied. The cells consisted of anode supported Sm-doped-ceria electrolyte bi-layer and cathode with 0.65 cm² effective area. Open-circuit voltage (OCV), V–I and P–I curves of the cells were measured over a temperature range from 400 to 800 °C, using H₂–3%H₂O as fuel and air as oxidant. Polarization potential of electrodes were measured with asymmetry three-electrode method during cell discharging. The results indicated that, Dy-SCF material cathode behaved with high catalytic activity for oxygen dissociation at low temperatures. For each cell with a particular cathode, there was a transition temperature, at which OCV of the cell reached the highest value. When temperature was higher than the transition temperature, OCV of the cell increases with decreasing temperature, whereas as temperature was lower than that, OCV decreased with lowering temperature.     

Low-temperature synthesis of La0.6Sr0.4Co0.2Fe0.8O3−δ perovskite powder via asymmetric sol–gel process and catalytic auto-combustion

La_0.6Sr_0.4Co_0.2Fe_0.8O_3−δ powder was synthesized by a combined EDTA-citrate complexing process via low-temperature auto-combustion synthesis with NH₄NO₃ as an oxidizer and a combustion trigger. Two novel methods were explored to improve this auto-combustion technology with reduced NH₄NO₃ addition: the use of La_0.6Sr_0.4Co_0.2Fe_0.8O_3−δ as the combustion catalyst and the application of asymmetric sol–gel process to provide the precursor with different NH₄NO₃ concentrations. The prepared perovskite powder was characterized by BET, SEM, XRD and iodometric titration techniques. The catalytic performance of the powder was also examined in the decomposition of peroxide hydrogen. Experimental results indicate that powders from catalytic combustion and asymmetric precursor routes have more advantages in terms of better crystallites, higher specific surface area, higher B-site valence state, improved sintering capability and better catalytic performance in peroxide hydrogen decomposition than that from the synthesis with uniform NH₄NO₃ distribution.     

Degradation mechanism analysis of Ba0.5Sr0.5Co0.8Fe0.2O3‐δ membranes at intermediate‐low temperatures

The degradation of the permeation flux of Ba_0.5Sr_0.5Co_0.8Fe_0.2O_3‐δ membranes has typically been attributed to the phase transformation of the material at intermediate temperatures. In this study, the effect of the interfacial oxygen exchange steps was considered to give an overall view of the degradation mechanism. The changes in the interfacial exchange resistances, bulk resistance, and morphologies of the membranes were investigated via physical characterizations and a permeation model. The interfacial oxygen exchange resistances increased more quickly with time than bulk resistance. Meanwhile, BaSO₄ particles were detected on both surfaces of the membranes, and their contents reached maximum at 650°C. However, after the membrane surfaces were coated by Sm_0.5Sr_0.5CoO_3‐δ porous layers, the interfacial oxygen exchange resistances kept constant and the degradation rates were slowed down. The degradation was predominated by the increase of interfacial oxygen exchange resistances induced by the enrichment of BaSO₄ particles on membrane surfaces. © 2015 American Institute of Chemical Engineers AIChE J, 61: 3879–3888, 2015     

Properties of Nb-doped SrCo0.8Fe0.2O3−d perovskites in oxidizing and reducing environments

The phase stability of SrCo_0.8Fe_0.2O_3−d perovskite doped with niobium was studied by in situ high-temperature X-ray diffraction in the temperature range of 30–1000 °C and oxygen partial pressure 0.2–10⁻⁵ atm. The stability of the cubic perovskite structure in a wide range of oxygen partial pressures is the main advantage of SrCo_0.8−xFe_0.2Nb_xO_3−d (x = 0.1–0.3) system in comparison with SrCo_0.8Fe_0.2O_3−d. It is suggested that equilibrium of the thermal expansion with changes of the oxygen non-stoichiometry leading to the same lattice parameters in the oxidizing and reducing environments at the catalytic temperatures is a necessary requirement for stable operation of perovskite as an oxygen-conducting membrane. In the case of SrCo_0.8−xFe_0.2Nb_xO_3−d perovskite this condition is met at x = 0.2. This makes the SrCo_0.6Fe_0.2Nb_0.2O_3−d composition promising for application as oxygen-conducting membrane.     

Composite cathodes of La0.9Ca0.1Ni0.5Co0.5O3-Ce0.8Sm0.2O1.9 for solid oxide fuel cells

The mixed ionic and electronic conductors of La_0.9Ca_0.1Ni_0.5Co_0.5O₃-Ce_0.8Sm_0.2O_1.9 (LCNC-SDC) are investigated systematically for potential application as a cathode for solid oxide fuel cells based on a Ce_0.8Sm_0.2O_1.9 (SDC) electrolyte. The electrochemical impedance spectroscopy (EIS) measurements are performed in air over the temperature range of 600-850 °C to determine the cathode polarization resistance. The exchange current densities for oxygen reduction reaction (ORR), determined from the low-field cyclic voltammetry, high-field cyclic voltammetry, and EIS data are systematically investigated. The activation energies (E_a) for ORR determined from the slope of Arrhenius plots are in the range of 102.33-150.73 kJ mol⁻¹ for LCNC-SDC composite cathodes. The experimental results found that LCNC-SDC (70:30) composite cathode has a maximum exchange current density and a minimum polarization resistance of 0.30 Ω cm² for 850 °C among LCNC-SDC composite cathodes.     

Sintering behaviour of La1−xSrxFeO3−δ mixed conductors

The sintering properties of La_1−xSr_xFeO_3−δ (x = 0.1, 0.25) mixed conductors have been investigated with particular emphasis on the effect of secondary phases due to cation non-stoichiometry (±5 mol% La excess and deficiency). Secondary phases, located at grain boundaries in cation non-stoichiometric materials, increased the sintering temperature compared to single-phase materials. Extensive swelling in final stage of sintering was observed in all materials, which resulted in micro-porous materials. The swelling was most pronounced in the phase pure and two-phase materials due to La-deficiency, while refractory secondary phases in La-excess materials inhibited both sintering, grain growth and swelling. In La-deficient materials, formation of molten secondary phases resulted in rapid swelling due to viscous flow. The present findings demonstrated the importance of controlling sintering temperature and time, as well as careful control of the cation stoichiometry of La_1−xSr_xFeO_3−δ in order to achieve fully dense and homogenous La_1−xSr_xFeO_3−δ ceramics.     

Synthesis, structural analysis and electrochemical performance of low-copper content La2Ni1−xCuxO4+δ materials as new cathodes for solid oxide fuel cells

In order to enhance the electrochemical performance of solid oxide fuel cells (SOFCs), La₂Ni_1−xCuO_4+δ (x = 0, 0.01, 0.02, 0.05 and 0.1) doped with copper in percentages, varying between 1% and 10%, were prepared following the modified Pechini method. The microstructure and morphology of the samples were analyzed by XRD and SEM. The electrochemical performance was followed by impedance spectroscopy. La₂Ni_0.99Cu_0.01O_4+δ samples showed good electrochemical and physicochemical properties with respect to the undoped material and is potentially a promising cathode. Indeed, doping with such small amounts of copper (1%) into the nickel site led to the formation of pure phases and stabilized the material before and after use at high temperature under air. In contrast, doping with higher amounts of copper (2%, 5% and 10%) led, after heating at 1000 °C for 48 h, to the formation of another phase resulting from the diffusion of copper into the YSZ electrolyte, limiting the interest to these materials as SOFC cathodes.     

A bi-layered composite cathode of La0.8Sr0.2MnO3-YSZ and La0.8Sr0.2MnO3-La0.4Ce0.6O1.8 for IT-SOFCs

A bi-layered composite cathode of La_0.8Sr_0.2MnO₃ (LSM)-YSZ and LSM-La_0.4Ce_0.6O_1.8 (LDC) was fabricated for anode-supported solid oxide fuel cells with a thin YSZ electrolyte film. The cell with the bi-layered composite cathode displayed better performance than the cell with the corresponding single-layered composite cathode of LSM-LDC or LSM-YSZ. At 650 °C, the cell with the bi-layered composite cathode gave a higher maximum power density than the cells with the single-layered LSM-LDC and LSM-YSZ composite cathodes, by 52% and 175%, respectively. The impedance spectra results show that the thin LSM-YSZ interlayer not only improves the cathode/electrolyte interface but also reduces the polarization resistance of the cathode. The activation energy for oxygen reduction on the bi-layered composite cathode is much smaller than that on LSM-YSZ composite cathode, and it is suggested that the special redox property of Ce⁴⁺/Ce³⁺ in LDC facilitates the oxygen reduction process on the bi-layered composite cathode. The cell with the bi-layered composite cathode operated quite stably during a 100 h run.