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an
rive,
004; a
(OT
lar d
se p
model. This model describes oxygen flux as a function of temperature, pressure, and oxygen recovery across composite OTMs. The
istry [3,4,5] resulted in an analytical solution for the ing the oxygen transport membrane (OTM) in partnership
with the U.S. Department of Energys National Energy
Technology Laboratory (NETL). The aim of this project is
iency of integrated
Solid State Ionics 174 (2004model predicts an optimum thickness for porous mixed-conducting layers to improve oxygen surface exchange. Layer thickness
depends on a number of parameters, such as pore size distribution, porosity, and tortuosity in each layer, and basic material
parameters, such as surface exchange rate and ambipolar conductivity. The transfer model shows the importance of optimizing these
parameters and a reactor design that enables a high mass transfer coefficient on the airside of the OTM element for optimum
performance.
D 2004 Elsevier B.V. All rights reserved.
PACS: 66.30; 81.05; 81.20; 82.20; 82.65
Keywords: Air separation; Oxygen permeation; Mixed ionic electron conductor; Surface exchange; Ambipolar conductivity; Diffusion; Ionic conduction;
Porous materials; Computational modeling; Membrane processes; Mass transfer
1. Introduction
The energy-related materials research group, led by
Masayuki Dokiya, conducted basic research on thermody-
namic and transport properties of complex oxides at the
former National Chemical Laboratory for Industry in
Tsukuba, Japan. The first oxide they evaluated,
La1yCayCrO3d, was considered a candidate materialfor interconnects in a solid oxide fuel cell. Oxygen
transport through that mixed conductor was undesirable
because it could result in oxidizing part of the fuel
without generating electrical power. The application of
irreversible thermodynamics [1,2] and point defect chem-
oxygen flux and oxygen chemical potential gradient [6,7].
This analytical solution was used to evaluate experimental
results [8].
Teraoka et al. [9,10] combined one of the basic
functions of interconnects (separating air from fuel) with
materials that were engineered for high ambipolar con-
ductivity. Their work started a new field of research:
mixed-conducting oxide membranes for air separation
[11]. This paper describes oxygen transport processes
through a mixed-conducting oxide membrane to achieve
air separation that produces oxygen as a product. The
model has been used in Praxair to determine some
preferred membrane architectures [12]. Praxair is develop-Oxygen transfer across compo
Bart A. v
Praxair, Inc., 175 East Park D
Received 30 March 2
Abstract
The transfer of oxygen across an oxygen transport membrane
across a boundary layer on the airside, surface exchange, ambipo
viscous flow of oxygen through the porous support. Each of the0167-2738/$ - see front matter D 2004 Elsevier B.V. All rights reserved.
doi:10.1016/j.ssi.2004.07.034
* Tel.: +1 716 897 2389; fax: +1 716 879 7931.
E-mail address: [email protected] transport membranes
Hassel*
Tonawanda, NY 14150, USA
ccepted 3 July 2004
M) is limited by a number of processes, such as mass transfer
iffusion through the mixed-conducting gas separation layer, and
rocesses was incorporated into a comprehensive oxygen transfer
) 253260
www.elsevier.com/locate/ssito reduce costs and improve the efficoxygen-fired coal gasification in combined cycle power
plants [1316].
2. Theory
2.1. Model outline
Fig. 1a and b shows a cross-section photograph and a
schematic drawing of an OTM that was used for model
development. The membrane consists of a dense gas
separation layer of a mixed-conducting oxide on a porous
support. Porous mixed-conducting oxide layers can be
applied on either the airside, oxygen product side, or both,
to improve the rate of oxygen transfer. Each porous layer
has its own thickness, pore size, porosity, and tortuosity.
B.A. van Hassel / Solid State Io254Fig. 1. (a) A cross-section of an OTM using scanning electron microscopy.
(b) A schematic diagram of the OTM used in model development.Compressed air is supplied to the side of the membrane with
the thin gas separation layer, while a low-pressure, high-
purity oxygen product is collected from the porous support
side.
2.2. Oxygen transport
The simultaneous transport of oxygen molecules inside
the pores and oxygen vacancies in the mixed-conducting
oxide phase of the membrane is described using an effective
medium approximation. Kenjo et al. [17], Murygin [18], and
Maggio et al. [19] first related this common approximation
to fuel cells, and Thorogood et al. [20] and Deng et al.
[21,22] applied it to the modeling of OTMs. The difference
between this study and previous works is shown in the
expressions used to describe oxygen transfer, and how the
boundary conditions are applied.
When modeling oxygen transfer across membranes with
a commercially viable oxygen flux, it is important to
account for the mass transfer resistance in the boundary
layer on the airside of the membrane. The following
expression was used to compute the oxygen flux across
the airside boundary layer around the OTM tube in axial
flow:
JO2 ShDO2;N2
IDShroud ODOTM Pair
RgTln
1 xO2;e1 xO2;s
1
where JO2=oxygen flux [mol/m2/s]; T=absolute temperature
[K]; Sh=Sherwood number []; DO2N2=binary diffusion co-
efficient for oxygen and nitrogen [m2/s]; ODOTM=outside
diameter of OTM tube [m]; IDShroud=inside diameter of
shroud around OTM tube [m]; Pair=airside absolute pressure
[Pa]; Rg=molar gas constant [J/(mol K)]; xO2,s=O2 mole
fraction outside the boundary layer []; xO2,e=O2 mole
fraction at the OTM wall [].
The Sherwood number was computed using well-known
correlations [23]. A positive oxygen flux indicates the
transport of oxygen from the airside of the membrane to the
oxygen product side.
The dusty gas model [24] was used to explain the
diffusion of oxygen gas against stagnant nitrogen on the
airside of the OTM, which resulted in the following
expression for the oxygen flux:
JO2 es
1
1
DKn;O2 1 xO2
Dmol;O2;N2
Pair
RgT
1
tpa
dxO2dx
2
where xO2=oxygen mole fraction []; Dmol,O2,N2=molecular
diffusion coefficient of oxygen in an O2/N2 mixture [m2/s];
DKn,O2=Knudsen diffusion coefficient of oxygen [m2/s];
Pair=airside absolute pressure [Pa]; e=porosity []; s=
nics 174 (2004) 253260tortuosity []; x=dimensionless coordinate (0bxb1) [];tpa=thickness of porous layer on the airside [m].
ate IoThe molecular diffusion coefficient was calculated from
[25]:
Dmol;O2;N2 0:00266 105T 32
Pair 103 MwO2MwN2
MwO2 MwN2
12
rO2;N2XD
3
where MwN2=molar weight of nitrogen [g/mol]; MwO2=
molar weight of oxygen [g/mol]; rO2,N2=characteristiclength [2]; XD=diffusion collision integral [].
The Knudsen diffusion coefficient is given by:
DKn;O2 2
3r
8RgT
pMO2
s4
where DKn,O2=Knudsen diffusion coefficient of oxygen [m2/
s]; Rg=molar gas constant [J/mol K]; T=absolute temper-
ature [K]; P=pressure [Pa]; r=pore radius [m]; MO2=
molecular weight of oxygen [kg/mol].
The ambipolar diffusion of oxygen ions through the
dense mixed-conducting oxide film results in the following
relation between oxygen flux and driving force:
JO2 ramb42F2
Dltg
5
where ramb=ambipolar conductivity [V1m1]; F=Faraday
constant [C/mol]; Dl=oxygen chemical potential dropacross dense gas separation layer [J/mol]; tg=thickness of
the dense gas separation layer [m].ramb stands for theaverage ambipolar conductivity (teltionrtot, with tel=elec-tronic transport number, tion=ionic transport number, and
rtot=total conductivity) in the oxygen chemical potentialgradient. The ambipolar conductivity was assumed to have
an Arrhenius dependence on temperature:
ramb r0ambeEambR
1T 1
1273:15 6
with ramb0 as the preexponential factor and Eamb as the
activation energy for the ambipolar conductivity.
The viscous flow of oxygen on the oxygen product
side of the OTM results in the following relationship
between the oxygen flux and the oxygen pressure
gradient:
JO2 esDKn;O2
1
RgT
1
tpp
dP
dx
e
sr2
8RgTgP
1
tpp
dP
dx
7
where Pl=pressure at the low-pressure side of the inert
support [Pa]; Ph=pressure at the high-pressure side of the
inert support [Pa]; tpp=thickness of the active porous layer
on oxygen side [m]; g=gas viscosity [N s/m2].The same equation is used to describe the oxygen flow
B.A. van Hassel / Solid Stthrough the inert porous support layers, but with the
appropriate thickness, porosity, and tortuosity.The exchange between oxygen in the gas phase, and the
oxygen ions in the mixed-conducting oxide is described
by:
JO2 kPnO2DlRgT
8
where k=rate constant for surface oxygen exchange
[mol O2/(m2 s (Pa/105)n)]; PO2=oxygen partial pressure
[Pa]; Dl=oxygen chemical potential drop across inter-face [J/mol]; n=exponent for oxygen partial pressure
dependence [].
The surface exchange rate constant was assumed to have
an Arrhenius dependence on temperature:
k k0eEkR 1T 11273:15 9
with k0 as the preexponential factor, and Ek as the activation
energy for surface exchange.
In the porous layers, an exchange occurs between the
oxygen gas molecules and the oxide ions, when there is a
difference in the oxygen chemical potential. Such an
exchange is accounted for by the following system of
differential equations:
Airside:
1
tpa
dJO2dx
kPnO2lg ls
RT
2er
10
1
tpa
dJO2
dx 2kPnO2
lg ls
RT
2er
11
O2 product side:
1
tpp
dJO2dx
kPnO2lg ls
RT
2er
12
1
tpp
dJO2
dx 2kPnO2
lg ls
RT
2er
13
where lgls=oxygen chemical potential differencebetween the gas phase and the mixed conducting oxide
phase [J/mol].
This results in two second-order differential equations for
each porous active layer. The oxygen flux in the gas phase is
indicated by JO2, and the flux of oxygen ions in the mixed-
conducting oxide is indicated by JO2.The following boundary conditions were used to solve
the system of differential equations and to obtain the oxygen
flux through the membrane.
On the airside, the oxygen partial pressure at the entrance
of the pore is equal to the pressure inside the boundary layer
with PO2,feed=Pair xO2,e:
nics 174 (2004) 253260 255lg RT ln PO2;feed 14
ate IoThere is also some exchange of oxygen in the gas
atmosphere and the oxygen ions in the mixed-conducting
oxide:
1 ess
ramb42F2
1
tpa
dlsdx
1 e kPnO2
lg ls
RT15
where ss=tortuosity of the solid phase in the porous mixedconducting oxide [].
This boundary condition that is based on a limited rate of
surface exchange is different from previous studies [1722],
in which it was assumed that the chemical potential of
oxygen in the gas phase was equal to the chemical potential
of oxygen in the solid at this interface. Tanner et al. [26]
applied a similar boundary condition in their two-dimen-
sional model of a porous composite electrode structure of a
solid oxide fuel cell.
At the location where the porous mixed-conducting
oxide layer comes into contact with the dense gas separation
layer, it is assumed that both oxygen chemical potentials in
the solid material are equal:
ls ls;dense 16Some oxygen diffuses all the way through the gas phase
in the pore into the dense gas separation layer interface.
Here oxygen can directly exchange with the oxygen ions in
the dense gas separation layer:
esg
1
1
DKn;O2 1 XO2
Dmol;O2;He
1
RgT
1
tpa
dPO2dx
ekPnO2
lg ls
RT
17where sg=tortuosity of the gas phase in the porous mixedconducting oxide [].
Similar boundary conditions are applied on the airside
and on the oxygen product side. The chemical potential of
oxygen in the dense gas separation layer on the oxygen
product side is equal to the chemical potential inside the
dense phase of the mixed-conducting oxide layer on the
oxygen product side:
ls ls;dense 18
Some oxide ions from the dense gas separation layer will
exchange with oxygen gas molecules, and these oxygen
molecules will diffuse and flow out of the porous mixed-
conducting oxide layer on the product side of the
membrane:
ekPnO2lg ls
RT e
sg
DKn;O2tpp
1
RT
1
tpp
dPO2;g
dx
esg
1
tpp
r2p
8RTgPO2;g
1
tpp
dPO2;g
dx
B.A. van Hassel / Solid St25619On the way out of this layer, there is a continuous
exchange between oxide ions and oxygen molecules, with a
net transfer of oxide ions as oxygen molecules into the gas
phase of the pore:
1 ess
ramb42F2
1
tpp
dlsdx
1 e kPnO2
lg ls
RT20
This boundary condition that is based on a limited rate of
surface exchange is also different from previous studies
[1722], in which it was assumed that the chemical potential
of oxygen in the gas phase was equal to the chemical
potential of oxygen in the solid at this interface.
As it exits the pore, the oxygen pressure is equal at the
interface between the mixed-conducting oxide layer and the
inert support:
lg RT ln PO2;inter 21
The oxygen flux through the dense mixed-conducting
layer must match the sum of the oxygen transported through
the dense phase of the porous mixed-conducting layer and
the oxygen directly exchanged with the dense gas separation
layer:
1 ess
ramb42F2
1
tpa
dlsdx
ekPnO2lg ls
RT
rion42F2
ls;h ls;ltd
22
1 ess
ramb42F2
1
tpp
dlsdx
ekPnO2lg ls
RT
rion42F2
ls;h ls;ltd
23
A pressure drop across each inert porous support layers
must be accounted for:
ramb42F2
ls;h ls;ltd
esup1
sg;sup1
DKn;O2tsup1
1
RT
dPO2;g
dx
esup1sg;sup1
1
tsup1
r 2sup1
8RTgPO2;g
dPO2;g
dx
24
ramb42F2
ls;h ls;ltd
esup2
sg;sup2
DKn;O2tsup2
1
RT
dPO2;g
dx
esup2sg;sup2
1
tsup2
r 2sup2
8RTgPO2;g
dPO2;g
nics 174 (2004) 253260dx
25
ramb42F2
ls;h ls;ltd
esup3
sg;sup3
DKn;O2tsup3
1
RT
dPO2;g
dx
surface exchange enhancement layer. Those layers are
considered inactive in oxygen transfer, since they are
Fig. 3 shows the oxygen flux versus the layer
thickness of the porous mixed-conducting oxide on the
airside of the membrane for various pore radii. Little
improvement in oxygen flux is achieved by mixed-
conducting oxide layers with large pore radii. Significant
improvements in oxygen flux are achieved by mixed-
Table 1
Operating conditions and oxygen viscosity
Temperature 1073.15 K
Airside total pressure 106 Pa
Oxygen mole fraction at airside 0.209
Oxygen product pressure 105 Pa
Oxygen viscosity at 1073.15 K 56.837106 Pa s
Table 3
High-performance oxygen ion transport membrane architecture
Porous mixed-conducting oxide layer on airside
Thickness 0.075 Am1.26 mmPorosity 0.32
Tortuosity gas phase 2.2
Tortuosity dense phase 2.2
Pore radius 0.00520 Am
Dense mixed-conducting gas separation layer
Thickness 10 Am
Porous mixed-conducting oxide layer on oxygen product side
Thickness 8 AmPorosity 0.32
Tortuosity gas phase 2.2
Tortuosity dense phase 2.2
Pore radius 0.05 Am
Porosity 0.32
Tortuosity gas phase 2.2
Pore radius 3 AmLayer 3
Thickness 1 mm
Porosity 0.32
Tortuosity gas phase 2.2
Pore radius 15 Am
B.A. van Hassel / Solid State Ionics 174 (2004) 253260 257located too far away from the dense gas separation layer
to have any influence on oxygen flux.
The system of differential equations with boundary
conditions at two points was solved numerically by using
a variable order, variable step-size finite difference method
with deferred corrections, which was implemented in the
bBVPFDQ solver from International Mathematics andStatistics (IMSL). Tables 13 provide a list of model
parameters that were used to determine preferred membrane
architectures.
3. Results and discussion
The oxygen partial pressure profiles in Fig. 2 were
computed with the model parameters found in Tables 13.
These profiles show an oxygen chemical potential differ-
ence between the gas phase and the mixed-conducting oxide
phase of the porous layer that serves as the driving force for
oxygen transfer. The thickness of the oxygen transfer zone
extended over about 8 Am in this example.
Table 2 esup3sg;sup3
1
tsup3
r2sup3
8RTgPO2;g
dPO2;gdx
26
where ei=porosity of support layer i []; si=tortuosity ofsupport layer i []; ti=thickness of support layer i [m].
Eqs. (24) Eqs. (25) Eqs. (26) show that the model allows
for three inert porous support layers below the porousModel parameters of a simulated OTM material
Ambipolar conductivity
at 1273.15K
214/V/m
Activation energy for ionic
conductivity
48 kJ/mol
Surface exchange coefficient
at 1273.15K
0.26 mol O2/
(m2 s (Pa/105)n)
Activation energy for surface
exchange coefficient
134 kJ/mol
Power dependence on oxygen
partial pressure
n=0.5Inert porous support layers
Layer 1
Thickness 6 AmPorosity 0.32
Tortuosity gas phase 2.2
Pore radius 0.3 AmLayer 2
Thickness 60 AmFig. 2. Oxygen partial pressure profiles across the mixed-conducting oxide
parts of the oxygen ion transport membrane. The difference in oxygen
partial pressure between the gas phase and the solid phase provides a
driving force for oxygen surface exchange, in which oxygen molecules
exiting the gas phase are incorporated in oxygen vacancies of the mixed-
conducting oxide layers.
Fig. 3. Oxygen flux versus layer thickness of the porous mixed-conducting oxide on the airside of the membrane. All other model parameters were kept
constant. The pore radius in the porous layer is indicated in micrometers. The oxygen flux is indicated in standard (273.15 K; 101,325 Pa) cubic centimeters per
minute per square centimeter (cm3/cm2/min).
B.A. van Hassel / Solid State Ionics 174 (2004) 253260258conducting oxide layers with small pore radii and Fig. 3
shows that there is an optimum layer thickness. Beyond
that thickness, the oxygen flux declines due to a gas
phase diffusion limitation. This optimum thickness shows
a complex relationship with the pore radius. The smaller
the pore radius, the thinner the porous layer must be to
achieve optimum oxygen flux.
Fig. 4 compares the optimum thickness/pore radius ratio
to the pore radius on the airside of the mixed-conducting
oxide layer. Fig. 4 demonstrates that the thickness appa-
rently has a one over square root dependence on the pore
radius. Fig. 4 also shows that a 10-fold change in the surface
exchange rate constant only results in about a factor 3.2
change in the optimum thickness/pore radius ratio, with a
smaller ratio for the material with the faster surface
exchange rate constant. A sensitivity analysis shows that
the following expression holds for the optimum thickness/
pore radius ratio for given values of the pore radius,porosity, tortuosity, materials parameters (ion conductivity
Fig. 4. The solid symbols show the optimum ratio of porous mixed-conducting
corresponding oxygen flux. The oxygen flux is indicated in standard (273.15 K;
min). The linear relation between the logarithm of that ratio and the logarithm ofand surface exchange rate), and operating conditions
(temperature and oxygen partial pressure):
t
r
optimum
1F
R
p
22
p Tp e EsigmaEk 2R 1T 11273:15 !
r0ambk0PnO2
1 ee
1
s1
rp
s27
When the activation energy for the ionic conductivity is
lower than the activation energy for the surface exchange,
the optimum thickness/pore radius ratio will decrease with
an increase in temperature. The optimum thickness/pore
radius ratio will increase with a decrease in oxygen partial
pressure (assuming nN0), which may occur when asignificant fraction of the oxygen is recovered from the air
stream. A material with a smaller ion conductivity/surface
exchange rate ratio will need a smaller thickness/pore radiusratio to achieve optimum flux. If the surface exchange rate
oxide layer thickness and pore radius, and the open symbols show the
101,325 Pa) cubic centimeters per minute per square centimeter (cm3/cm2/
the pore radius is consistent with Eq. (27).
layer thickness is adjusted to its optimum value.
research group, especially Yukiko and Masayuki Dokiya,
for their hospitality and for letting me perform basic
this copyrighted paper.
ate IoReferences
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An oxygen transport model of composite OTMs must
incorporate mass transfer across a boundary layer on the
airside of the membrane, surface exchange, ambipolar
diffusion through the mixed-conducting gas separation
layer, and viscous flow of oxygen through the porous
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layers would be required.
Fig. 4 shows both the optimum thickness/pore radius
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B.A. van Hassel / Solid State Ionics 174 (2004) 253260260
Oxygen transfer across composite oxygen transport membranesIntroductionTheoryModel outlineOxygen transport
Results and discussionConclusionsAcknowledgementReferences