Development of a Membrane Module Prototype for Oxygen Separation in Industrial Applications

The integration of oxygen transport membranes in industrial processes can lead to energy and economic advantages, but proof of concept membrane modules are highly necessary to demonstrate the feasibility of this technology. In this work, we describe the development of a lab-scale module through a comprehensive study that takes into consideration all the relevant technological aspects to achieve a prototype ready to be operated in industrial environment. We employed scalable techniques to manufacture planar La0.6Sr0.4Co0.2Fe0.8O3-delta membrane components suitable for the application in both 3- and 4-end mode, designed with a geometry that guarantees a failure probability under real operating conditions as low as 2.2 x 10(-6). The asymmetric membranes that act as separation layers showed a permeation of approx. 3 NmL/min/cm(2) at 900 degrees C in air/He gradient, with a remarkable stability up to 720 h, and we used permeation results to develop a CFD model that describes the influence of the working conditions on the module performance. The housing of the membrane component is an Inconel 625 case joined to the membrane component by means of a custom-developed glass-ceramic sealant that exhibited a remarkable thermo-chemical compatibility both with metal and ceramic, despite the appearance of chemical strain in LSCF at high temperature. The multi-disciplinary approach followed in this work is suitable to be adapted to other module concepts based on membrane components with different dimensions, layouts or materials.