Oxygen-Permeable Membrane and Method for Its Manufacture

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This invention introduces a composite membrane designed for selective gas separation, particularly oxygen. The membrane consists of a multi-layer structure: a mechanically robust, highly porous base layer, one or more porous intermediate ceramic layers with a much smaller pore size, and an ultrathin, gas-tight functional layer made from advanced mixed-conductive materials (like perovskites or fluorites). The process for manufacturing ensures mechanical stability, chemical compatibility, high gas permeability, and selectivity, ultimately enabling effective separation of oxygen from gas streams.

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

• Oxygen separation from air to supply high-purity oxygen for industrial, medical, or combustion processes.
• CO2 capture in fossil-fueled power plants by improving combustion processes through pure oxygen supply (oxyfuel combustion).
• Integration in hydrogen production plants where selective oxygen removal enhances reforming processes.
• Gas separation in chemical industries where selective oxygen or other gas extraction is needed.
• Air separation units for metallurgy, glass production, or semiconductor manufacturing.

BenefitsContent extracted from patent full text and abstract with AI.

• Significantly higher oxygen permeability and selectivity compared to traditional membranes, improving process efficiency.
• High mechanical and chemical stability due to the multilayer ceramic and/or metal structure, making it suitable for harsh industrial environments.
• Material and cost savings owing to the ultrathin functional separation layer without sacrificing performance.
• Scalable and compatible with various carrier and functional materials, offering flexibility for different industrial requirements.
• Enhanced membrane longevity and operational reliability, even under high temperatures and corrosive conditions.

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Patent Abstract

The invention relates to a composite membrane for selective gas separation, comprising a layer system having a through-and-through porous, mechanically stable carrier layer, which has an average pore size in the µm range, further having at least one through-and-through porous intermediate layer, which is disposed on the carrier layer and has an average pore size in the range between 2 and 200 nm, and further having a gas-tight functional layer, which is disposed on the intermediate layer and is made of mixed-conductive material having a maximum layer thickness of 1 µm. The carrier layer comprises structural ceramics, a metal or a cermet and has a layer thickness of no more than 1 mm. The intermediate layer is present in a total layer thickness of no more than 100 µm and has an average pore size in the range of 10 and 100 nm. The functional layer comprises a perovskite, a fluorite, or a material having a K2NiF4 structure, such as La1-xSrxCo1-yFeyO3-8 (LSCF). The layer thickness of the functional layer is no more than 50 nm, particularly between 25 and 400 nm. In order to produce said composite membrane, at least one porous intermediate layer is applied onto a through-and-through porous, mechanically stable carrier layer, which has an average pore size in the µm range, said intermediate layer having an average pore size in the range between 2 and 200 nm. A further gas-tight, functional layer made of a mixed-conductive material and having a maximum layer thickness of 1 µm is applied onto said intermediate layer.