Mixed ions and electron conducting gas separation membrane and process for producing the same

Simple SummaryContent extracted from patent full text and abstract with AI.

This invention relates to an advanced gas separation membrane composed of a porous metallic support and a thin functional ceramic layer that conducts both ions and electrons. The metallic substrate (e.g., NiCoCrAlY or FeCrAlY alloys) is specially chosen for high-temperature stability and mechanical strength, while the functional layer (typically based on perovskite or fluorite-type ceramics such as LSCF or BSCF) provides selective and efficient separation of gases like oxygen or hydrogen. The membrane is engineered to excel in high-temperature applications and is manufactured using techniques such as low-pressure plasma spraying to produce dense, thin, and durable gas-tight layers without additional sintering.

Use CasesContent extracted from patent full text and abstract with AI.

• Oxygen generation and purification for medical or industrial use.
• Separation of oxygen from air for use in combustion processes (e.g., oxy-fuel combustion in power plants with CO2 sequestration).
• Hydrogen or syngas (H2 + CO) production in chemical plants or refineries via membrane reactors.
• Selective separation in chemical synthesis processes, such as oxidative coupling of methane or synthesis gas production from hydrocarbons.
• Tail-gas treatment or NOx decomposition in exhaust gas cleaning.
• Integration in membrane reactors for improved efficiency in chemical conversions under reducing or high-temperature conditions.

BenefitsContent extracted from patent full text and abstract with AI.

• High selectivity and permeation rates for specific gases such as oxygen or hydrogen, even at elevated temperatures.
• Long-term mechanical and chemical stability due to the robust metallic support and optimized thermal expansion matching with the ceramic layer.
• Ability to fabricate very thin, dense membranes that enable high fluxes, improving economic viability and reducing material usage.
• No need for high-temperature post-sintering, reducing the risk of defects such as cracks or undesired densification, leading to higher yields and reliability in production.
• Enhanced compatibility with membrane reactors and flexible integration into industrial gas separation and chemical processing setups.
• Potential for reduced energy consumption and better process efficiency compared to conventional separation technologies, especially at high temperatures.

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Patent Abstract

An asymmetrical membrane comprises porous support structure and functional layer. The porous support structure contains metal which is capable of forming stabilized oxide layer at more than 600[deg] C under air, and carries layer. The carries layer has porosity of more than 30 vol.%, and thermal expansion coefficient of 12x 10 -> 6> and 16x 10 -> 6> K -> 1>. The film thickness of support structure is 0.5-2 mm. The functional layer contains mixed ion and electroconductive material. The functional layer has layer thickness of 0.3-200 mu m. An asymmetrical membrane comprises porous support structure and functional layer. The porous support structure contains metal which is capable of forming stabilized oxide layer at more than 600[deg] C under air, and carries layer. The carries layer has porosity of more than 30 vol.%, and thermal expansion coefficient of 12x 10 -> 6> and 16x 10 -> 6> K -> 1>. The film thickness of support structure is 0.5-2 mm. The functional layer contains mixed ion and electroconductive material. The functional layer has layer thickness of 0.3-200 mu m. The permeation flux of asymmetric membrane at more than 750[deg] C of 0.1 ml/(cm 2>.minute), and at more than 850[deg] C of 0.2 ml/(cm 2>.minute) or more. An independent claim is included for manufacture of asymmetrical membrane.