Creep behavior of porous La0.6Sr0.4Co0.2Fe0.8O3-δ substrate material for oxygen separation application

Advanced oxygen transport membrane designs consist of a thin functional layer supported by a porous substrate material that carries mechanical loads. Creep deformation behavior is to be assessed to warrant a long-term reliable operation at elevated temperatures. Aiming towards an asymmetric composite, the current study reports and compares the creep behavior of La_0.6Sr_0.4Co_0.2Fe_0.8O_3-δ (LSCF) perovskite porous substrate material with different porosity and pore structures in air for a temperature range of 800–1000?°C. A porosity and pore structure independent average stress exponent and activation energy are derived from the deformation data, both being representative for the LSCF material. To investigate the structural stability of the dense layer in an asymmetric membrane, sandwich samples of Ba_0.5Sr_0.5Co_0.8Fe_0.2O_3-δ (BSCF) and La_0.6Sr_0.4Co_0.2Fe_0.8O_3-δ (LSCF) with porous substrate and dense layers on both side were tested by three-point bending with respect to creep rupture behavior of the dense layer. Creep rupture cracks were observed in the tensile surface of BSCF, but not in the case of LSCF.     

Tuning Ba0.5Sr0.5Co0.8Fe0.2O3-δ cathode to high stability and activity via Ce-doping for ceramic fuel cells

Ba_0.5Sr_0.5Co_0.8Fe_0.2O_3-δ (BSCF) fuel-cell cathode stands out because of its ultrahigh ionic conductivity and excellent electrocatalytic activity, but it is still very subject to instability. Here, a new strategy of Ce doping is proposed to boost the stability and activity of the BSCF cathode. A one-pot combustion method is employed to synthesize (Ba_0.5Sr_0.5)_1–xCe_xCo_0.8Fe_0.2O_3-δ (x=0–0.2) cathodes. Both BSCF and (Ba_0.5Sr_0.5)_0.9Ce_0.1Co_0.8Fe_0.2O_3-δ have a cubic perovskite structure. (Ba_0.5Sr_0.5)_0.8Ce_0.2Co_0.8Fe_0.2O_3-δ shows two phases of cubic perovskite and fluorite ceria. Proper Ce doping can boost the electrical conductivity of BSCF, and can dramatically reduce the polarization resistance of BSCF cathode. Ce doping significantly improved BSCF cathode long-term stability by 160 h. Moreover, ten-percent Ce doping in BSCF highly improves single-cell output performance from 516.33 mW cm^?2 to 629.75 mW cm^?2 at 750 °C. The results reveal that Ce doping as a potential strategy for enhancing the stability and activity of BSCF cathode is promising.     

Thermochemical stability of Fe- and co-functionalized perovskite-type SrTiO3 oxygen transport membrane materials in syngas conditions

The materials typically used for oxygen transport membranes, Ba_0.5Sr_0.5Co_0.8Fe_0.2O_3?δ (BSCF) and La_0.6Sr_0.4Co_0.2Fe_0.8O₃ (LSCF) tend to decompose due to their low thermochemical stability under reducing atmosphere. Fe- and Co-doped SrTiO₃ (SrTi_1-x-yCo_xFe_yO_3-δ, x + y ≤ 0.35) (STCF) materials showing an oxygen transport comparable to LSCF have great potential for application in ion-transport-devices. In this study, the thermochemical stability of pure perovskite-structured STCF was investigated after annealing in a syngas atmosphere at 600–900 °C. The phase composition of the materials after annealing was characterized by means of X-ray diffraction (XRD). The thermodynamic activities of SrO, FeO, and CoO in the STCF materials were evaluated using Knudsen effusion mass spectrometry (KEMS). Co-doped SrTiO₃ (STC) materials were not stable after annealing in the syngas atmosphere above 5 mol% Co-substitution. Ruddlesden-Popper-like phases and SrCO₃ were detected after annealing at 600 °C. In contrast, Fe substitution (STF) showed good stability after annealing in syngas upto 35 mol% substitution.     

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.     

An architectural approach to the oxygen permeability of a La0.6Sr0.4Fe0.9Ga0.1O3−δ perovskite membrane

Multilayer membranes based on La_0.6Sr_0.4Fe_0.9Ga_0.1O_3−δ (LSFG) and La_0.6Sr_0.4Co_0.8Fe_0.2O_3−δ (LSCF) perovskite materials were fabricated to study the impact of membrane architecture on the oxygen permeability. Thick dense membrane and asymmetric membranes were shaped by tape casting and stacked to reach the desired architecture. Asymmetric membranes composed of a thin dense LSFG layer (120 μm) and a thick porous support layer (820 μm) of the same material were co-sintered to obtain crack-free and flat membranes. The use of large corn-starch particles (14 μm) as pore forming agent to the tape-casting slurries resulted in a connected porosity in the sintered support layer with low gas diffusion resistance. Oxygen permeation measurements in an air/argon gradient between 800 and 925 °C showed that the thickness of self-supported LSFG membranes was not the determining factor in the membrane performance for our testing conditions. A catalytic layer of La_0.6Sr_0.4Co_0.8Fe_0.2O_3−δ (LSCF), deposited on the membrane surfaces to catalyze the oxygen exchange reactions, leads to a significant increase of oxygen permeation rates. As the membrane thickness had no effect even if a catalyst coating was used, surface-exchange reactions were thought to be still limiting for the oxygen permeation fluxes. Thus, the improvement of surface activity of LSFG membrane was found to be a key point to reach higher oxygen permeation fluxes.     

Selection of oxygen permeation models for different mixed ionic‐electronic conducting membranes

Permeation data of several mixed ionic‐electronic conducting (MIEC) membranes were analyzed by two oxygen permeation models (i.e., Zhu's model and Xu–Thomson's model), respectively, to find a concise method to guide the choice of permeation models. We found that Zhu's model can well fit the permeation data of perovskite‐type membranes, like Ba_0.5Sr_0.5Co_0.8Fe_0.2O_3‐δ (BSCF) and BaCe_0.05Fe_0.95O_3‐δ (BCF), and dual‐phase membranes, like 75 wt % Ce_0.85Sm_0.15O_1.925–25 wt % Sm_0.6Sr_0.4Al_0.3Fe_0.7O_3‐δ (SDC‐SSAF), whose oxygen vacancy concentrations are almost independent of the oxygen partial pressure at elevated temperatures. However, Zhu's model was not appropriate for membranes whose oxygen vacancy concentration changed obviously with oxygen partial pressure at elevated temperatures, such as La_0.6Sr_0.4Co_0.2Fe_0.8O_3‐δ (LSCF) and La_0.7Sr_0.3CoO_3‐δ (LSC). On the contrary, Xu–Thomson's model can fit the data of LSCF and LSC well, but it is inapplicable for BSCF, BCF, and SDC‐SSAF. Therefore, the dependence of oxygen vacancy concentration on oxygen partial pressure was suggested as an index for the selection of the permeation models. © 2017 American Institute of Chemical Engineers AIChE J, 63: 4043–4053, 2017     

A case study of mechanical properties of perovskite-structured Ba0.5Sr0.5Co0.8Fe0.2O3−δ oxygen transport membrane

This study has investigated mechanical properties of perovskite-structured Ba_0.5Sr_0.5Co_0.8Fe_0.2O_3-δ (BSCF) oxygen transport membrane. The Young’s modulus and fracture toughness are determined by both macroscopic-scale and microscopic-scale methods. Both three-point and ring-on-ring bending tests as macroscopic-scale methods produce broadly similar results with a Young’s modulus, which is lower than that measured from micro-indentation method under a 10 N load. Young’s modulus and fracture toughness of BSCF show strongly dependent of the porosity. However, the fracture toughness of BSCF is independent of grain size. The fracture toughness determined by macroscopic-scale method is similar with that measured by microscopic-scale method. The crack shape of BSCF under a 10 N load is determined to be a median-radial mode. The intrinsic Young’s modulus and fracture toughness are determined to be 105.6 GPa and 1.49 MPa m^0.5, respectively, according the Minimum Solid Area (MSA) model. Annealing decreases the fracture toughness of BSCF between RT and 800 °C.     

Subcritical crack growth behavior of a perovskite‐structured Ba0.5Sr0.5Co0.8Fe0.2O3−δ oxygen transport membrane

This paper herein studies subcritical crack growth (SCG) behavior of a perovskite‐structured Ba_0.5Sr_0.5Co_0.8Fe_0.2O_3?δ (BSCF) as an oxygen transport membrane material. The SCG behavior of BSCF is evaluated by a constant load method and constant stress rate method at room temperature (RT) and 800°C in air, respectively. The low crack velocity measurements are carried out by ring‐on‐ring bending tests while the high crack velocity measurements by compact tension tests. The stress rates vary approximately from 0.1012 to 101.2 MPa/min. The fracture stress increases with increasing stress rate at 800°C. The SCG parameter, n, of BSCF is determined to be 24.32 and 13.83 at RT and 800°C in air, respectively. This indicates that BSCF is more susceptible to SCG at 800°C. The strength‐probability‐time (SPT) diagram is constructed for design proposes. The stress for a lifetime of 40 years should not exceed 27.21 MPa at RT or 4.53 MPa at 800°C to assure a failure probability below 1%.     

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.     

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.     

Mechanical behavior of ferroelastic porous La0.6Sr0.4Co0.2Fe0.8O3−δ prepared with different pore formers

The present work investigated the mechanical behavior of porous La_0.6Sr_0.4Co_0.2 Fe_0.8O_3−δ LSCF under uniaxial compression. The porous (LSCF) samples with the same grain size but different porous structures with 1.5–41% of porosity were prepared using three different pore formers. All the samples had ferroelastic domains and exhibited ferroelastic mechanical behaviors under uniaxial compression. Initial and loading moduli as well as critical stress monotonically decreased and remnant strain increased with increasing the porosity. The initial modulus can be determined by the actual porosity regardless of porous structure or grain size, whereas the other properties were more sensitive to experimental condition such as loading rate and maximum applied stress. Compressive fracture strength could be significantly influenced by porous structure.     

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.     

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.     

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.     

Modeling of the performance of BSCF capillary membranes in four-end and three-end integration mode

Owing to their high surface-to-volume ratio, there has been an increasing research interest in mixed ionic–electronic conducting (MIEC) capillary membranes for large-scale high temperature oxygen separation applications. They offer an energy-efficient solution for high temperature combustion processes in oxy-fuel and pre-combustion CO₂ capture technologies used in fossil fuel power plants. In order to assess the effectiveness of these membranes in power plant applications, the impact of the geometry of Ba_0.5Sr_0.5Co_0.8Fe_0.2O_3?δ (BSCF) capillaries on their performance in the three-end and four-end integration modes has been investigated and thoroughly discussed. The model's parameters were derived from four-end mode lab-scale experiments using gas-tight, macrovoid free and sulfur-free BSCF capillary membranes that were prepared by a phase-inversion spinning technique. The results of this modeling study revealed that in the four-end mode higher average oxygen fluxes and smaller total membrane areas can be obtained than in the three-end mode. This is due to the higher pO₂ gradient across the membrane wall.     

Oxygen nonstoichiometry in Pr1−xSrxCo0.2B0.8O3−δ (B = Mn,Fe, x = 0.2, 0.4) perovskite oxides

Thermogravimetric analysis was applied to the study of oxygen nonstoichiometry of perovskite oxides of the compositions Pr_0.8Sr_0.2Co_0.2Mn_0.8O_3−δ and Pr_1−xSr_xCo_0.2Fe_0.8O_3−δ (x = 0.2, 0.4). The measurements were performed in the temperature range from room temperature to 1200 °C in various atmospheres: oxygen, air and argon. The recorded weight loss corresponds to the loss of lattice oxygen. The magnitude of oxygen loss increased and the temperature at which oxygen loss became significant decreased with increasing Sr content. The loss of lattice oxygen became more significant as the oxygen partial pressure decreased. For the same pO₂ and level of Sr doping, the Fe-containing composition became more easily oxygen deficient than the corresponding Mn-containing one, suggesting that Fe is more resistant to oxidation from the trivalent to the tetravalent state than Mn. Electrical conductivity measurements, performed in air, showed that the temperature ranges at which conductivity decrease was observed, correspond fairly well with those ranges where weight loss was detected.     

Ba1−xPrxCo1−yFeyO3−δ as cathode materials for low temperature solid oxide fuel cells

Ba_1−xPr_xCo_1−yFe_yO_3−δ (BPCF) perovskite oxides have been synthesized and investigated as cathode materials for low temperature solid oxide fuel cells (LT-SOFCs). Compared with those of Ba_0.5Sr_0.5Co_0.8Fe_0.2O_3−δ (BSCF) and Sm_0.5Sr_0.5CoO₃ (SSCo) cathode materials, BPCF has a lower polarization resistance at decreased temperatures. In particular, Ba_0.5Pr_0.5Co_0.8Fe_0.2O_3−δ showed the lowest polarization loss among the different compositions as a cathode material for LT-SOFCs. The area specific resistance (ASR) of Ba_0.5Pr_0.5Co_0.8Fe_0.2O_3−δ as a cathode material is 0.70 and 0.185 Ω cm² at 500 °C and 550 °C, respectively. The maximum power density of the cell BPCF/SDC/Ni-SDC with humidified hydrogen as fuel and air as oxidant reaches 860 mW cm⁻² at 650 °C.     

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.     

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.