Advanced Hydrogen Transport Membranes for Vision 21 Fossil Fuel Plants

The objective of this project was to develop an environmentally benign, inexpensive, and efficient method for separating hydrogen from gas mixtures produced during industrial processes, such as coal gasification. A family of hydrogen separation membranes was developed including single phase mixed conducting ceramics, ceramic/ceramic composites, cermet membranes, cermet membranes containing a hydrogen permeable metal, and intermediate temperature composite layered membranes. Each membrane type had different operating parameters, advantages, and disadvantages that were documented over the course of the project. Research on these membranes progressed from ceramics to cermets to intermediate temperature composite layered membranes. During this progression performance was increased from 0.01 mL x min{sup -1} x cm{sup -2} up to 423 mL x min{sup -1} x cm{sup -2}. Eltron and team membranes not only developed each membrane type, but also membrane surface catalysis and impurity tolerance, creation of thin film membranes, alternative applications such as membrane promoted alkane dehydrogenation, demonstration of scale-up testing, and complete engineering documentation including process and mechanical considerations necessary for inclusion of Eltron membranes in a full scale integrated gasification combined cycle power plant. The results of this project directly led to a new $15 million program funded by the Department of Energy. This new project will focus exclusively on scale-up of this technology as part of the FutureGen initiative

Advanced Hydrogen Transport Membranes for Vision 21 Fossil Fuel Plants

Eltron Research Inc., and team members CoorsTek, McDermott Technology, Inc., Sued Chemie, Argonne National Laboratory, and Oak Ridge National Laboratory are developing an environmentally benign, inexpensive, and efficient method for separating hydrogen from gas mixtures produced during industrial processes, such as coal gasification. This objective is being pursued using dense membranes based in part on Eltron-patented ceramic materials with a demonstrated ability for proton and electron conduction. The technical goals are being addressed by modifying single-phase and composite membrane composition and microstructure to maximize proton and electron conductivity without loss of material stability. Ultimately, these materials must enable hydrogen separation at practical rates under ambient and high-pressure conditions, without deactivation in the presence of feedstream components such as carbon dioxide, water, and sulfur. This project was motivated by the National Energy Technology Laboratory (NETL) Vision 21 initiative which seeks to economically eliminate environmental concerns associated with the use of fossil fuels. The proposed technology addresses the DOE Vision 21 initiative in two ways. First, this process offers a relatively inexpensive solution for pure hydrogen separation that can be easily incorporated into Vision 21 fossil fuel plants. Second, this process could reduce the cost of hydrogen, which is a clean burning fuel under increasing demand as supporting technologies are developed for hydrogen utilization and storage. Additional motivation for this project arises from the potential of this technology for other applications. Membranes testing during this reporting period were greater than 1 mm thick and had the general perovskite composition AB{sub 1-x}B'{sub x}O{sub 3-{delta}}, where 0.05 {<=} x {<=} 0.3. These materials demonstrated hydrogen separation rates between 1 and 2 mL/min/cm{sup 2}, which represents roughly 20% of the target goal for membranes of this thickness. The sintered membranes were greater than 95% dense, but the phase purity decreased with increasing dopant concentration. The quantity of dopant incorporated into the perovskite phase was roughly constant, with excess dopant forming an additional phase. Composite materials with distinct ceramic and metallic phases, and thin film perovskites (100 {micro}m) also were successfully prepared, but have not yet been tested for hydrogen transport. Finally, porous platinum was identified as a excellent catalyst for evaluation of membrane materials, however, lower cost nickel catalyst systems are being developed

Advanced Hydrogen Transport Membranes for Vision 21 Fossil Fuel Plants

Seeks to economically eliminate the environmental concerns associated with the use of fossil fuels

Hydrogen Separation Membranes for Vision 21 Fossil Fuel Plants

Eltron Research and team members CoorsTek, McDermott Technology, Sued Chemie, Argonne National Laboratory, and Oak Ridge National Laboratory are developing an environmentally benign, inexpensive, and efficient method for separating hydrogen from gas mixtures produced during industrial processes, such as coal gasification. This objective is being pursued using dense membranes based in part on Eltron-patented ceramic materials with a demonstrated ability for proton and electron conduction. The technical goals are being addressed by modifying single-phase and composite membrane composition and microstructure to maximize proton and electron conductivity without loss of material stability. Ultimately, these materials must enable hydrogen separation at practical rates under ambient and high-pressure conditions, without deactivation in the presence of feedstream components such as carbon dioxide, water, and sulfur. This project was motivated by the Department of Energy (DOE) National Energy Technology Laboratory (NETL) Vision 21 initiative which seeks to economically eliminate environmental concerns associated with the use of fossil fuels. The proposed technology addresses the DOE Vision 21 initiative in two ways. First, this process offers a relatively inexpensive solution for pure hydrogen separation that can be easily incorporated into Vision 21 fossil fuel plants. Second, this process could reduce the cost of hydrogen, which is a clean burning fuel under increasing demand as supporting technologies are developed for hydrogen utilization and storage. Additional motivation for this project arises from the potential of this technology for other applications. By appropriately changing the catalysts coupled with the membrane, essentially the same system can be used to facilitate alkane dehydrogenation and coupling, aromatics processing, and hydrogen sulfide decomposition

Advanced Hydrogen Transport Membranes for Vision 21 Fossil Fuel Plants

The objective of this project is to develop an environmentally benign, inexpensive, and efficient method for separating hydrogen from gas mixtures produced during industrial processes, such as coal gasification. Currently, this project is focusing on four basic categories of dense membranes: (1) mixed conducting ceramic/ceramic composites, (2) mixed conducting ceramic/metal (cermet) composites, (3) cermets with hydrogen permeable metals, and (4) layered composites with hydrogen permeable alloys. The primary technical challenge in achieving the goals of this project will be to optimize membrane composition to enable practical hydrogen separation rates and chemical stability. Other key aspects of this developing technology include catalysis, ceramic processing methods, and separation unit design operating under high pressure. To achieve these technical goals, Eltron Research Inc. has organized a consortium consisting of CoorsTek, Sued Chemie, Inc. (SCI), Argonne National Laboratory (ANL), and NORAM. Hydrogen permeation rates in excess of 50 mL {center_dot} min{sup -1} {center_dot} cm{sup 2} at {approx}440 C were routinely achieved under less than optimal experimental conditions using a range of membrane compositions. Factors that limit the maximum permeation attainable were determined to be mass transport resistance of H{sub 2} to and from the membrane surface, as well as surface contamination. Mass transport resistance was partially overcome by increasing the feed and sweep gas flow rates to greater than five liters per minute. Under these experimental conditions, H2 permeation rates in excess of 350 mL {center_dot} min{sup -1} {center_dot} cm{sup 2} at {approx}440 C were attained. These results are presented in this report, in addition to progress with cermets, thin film fabrication, catalyst development, and H{sub 2} separation unit scale up

Advanced Hydrogen Transport Membranes for Vision 21 Fossil Fuel Plants

Eltron Research Inc., and team members, are developing an environmentally benign, inexpensive, and efficient method for separating hydrogen from gas mixtures produced during industrial processes, such as coal gasification. This project was motivated by the National Energy Technology Laboratory (NETL) Vision 21 initiative which seeks to economically eliminate environmental concerns associated with the use of fossil fuels. This objective is being pursued using dense membranes based in part on Eltron-patented ceramic materials with a demonstrated ability for proton and electron conduction. The technical goals are being addressed by modifying single-phase and composite membrane composition and microstructure to maximize proton and electron conductivity without loss of material stability. Ultimately, these materials must enable hydrogen separation at practical rates under ambient and high-pressure conditions, without deactivation in the presence of feedstream components such as carbon dioxide, water, and sulfur. During this quarter, ceramic, cermet (ceramic/metal), and thin film membranes were prepared, characterized, and evaluated for H{sub 2} transport. For selected ceramic membrane compositions an optimum range for transition metal doping was identified, and it was determined that highest proton conductivity occurred for two-phase ceramic materials. Furthermore, a relationship between transition metal dopant atomic number and conductivity was observed. Ambipolar conductivities of {approx}6 x 10{sup -3} S/cm were achieved for these materials, and {approx} 1-mm thick membranes generated H{sub 2} transport rates as high as 0.3 mL/min/cm{sup 2}. Cermet membranes during this quarter were found to have a maximum conductivity of 3 x 10{sup -3} S/cm, which occurred at a metal phase contact of 36 vol.%. Homogeneous dense thin films were successfully prepared by tape casting and spin coating; however, there remains an unacceptably high difference in shrinkage rates between the film and support, which led to membrane instability. Further improvements in high pressure membrane seals also were achieved during this quarter, and a maximum pressure of 100 psig was attained. CoorsTek optimized many of the processing variables relevant to manufacturing scale production of ceramic H{sub 2} transport membranes, and SCI used their expertise to deposit a range of catalysts compositions onto ceramic membrane surfaces. Finally, MTI compiled relevant information regarding Vision 21 fossil fuel plant operation parameters, which will be used as a starting point for assessing the economics of incorporating a H{sub 2} separation unit

Advanced Hydrogen Transport Membranes for Vision 21 Fossil Fuels Plants

Eltron Research Inc. and team members CoorsTek, Sued Chemie, and Argonne National Laboratory are developing an environmentally benign, inexpensive, and efficient method for separating hydrogen from gas mixtures produced during industrial processes, such as coal gasification. This project was motivated by the National Energy Technology Laboratory (NETL) Vision 21 initiative, which seeks to economically eliminate environmental concerns associated with the use of fossil fuels. Currently, this project is focusing on four basic categories of dense membranes: (1) mixed conducting ceramic/ceramic composites, (2) mixed conducting ceramic/metal (cermet) composites, (3) cermets with hydrogen permeable metals, and (4) layered composites containing hydrogen permeable alloys. Ultimately, these materials must enable hydrogen separation at practical rates under ambient and high-pressure conditions, without deactivation in the presence of feedstream components such as carbon dioxide, water, and sulfur. This report presents hydrogen permeation data during long term tests and tests at high pressure in addition to progress with cermet, ceramic/ceramic, and thin film membranes

ADVANCED HYDROGEN TRANSPORT MEMBRANES FOR VISION 21 FOSSIL FUEL PLANTS

Eltron Research Inc., and team members, are developing an environmentally benign, inexpensive, and efficient method for separating hydrogen from gas mixtures produced during industrial processes, such as coal gasification. This project was motivated by the National Energy Technology Laboratory (NETL) Vision 21 initiative which seeks to economically eliminate environmental concerns associated with the use of fossil fuels. This objective is being pursued using dense membranes based in part on Eltron-patented ceramic materials with a demonstrated ability for proton and electron conduction. The technical goals are being addressed by modifying single-phase and composite membrane composition and microstructure to maximize proton and electron conductivity without loss of material stability. Ultimately, these materials must enable hydrogen separation at practical rates under ambient and high-pressure conditions, without deactivation in the presence of feedstream components such as carbon dioxide, water, and sulfur. During this quarter, ceramic, cermet (ceramic/metal), and thin film membranes were prepared, characterized, and evaluated for H{sub 2} transport. For selected ceramic membrane compositions an optimum range for transition metal doping was identified, and it was determined that highest proton conductivity occurred for two-phase ceramic materials. Furthermore, a relationship between transition metal dopant atomic number and conductivity was observed. Ambipolar conductivities of {approx}6 x 10{sup -3} S/cm were achieved for these materials, and {approx} 1-mm thick membranes generated H{sub 2} transport rates as high as 0.3 mL/min/cm{sup 2}. Cermet membranes during this quarter were found to have a maximum conductivity of 3 x 10{sup -3} S/cm, which occurred at a metal phase contact of 36 vol.%. Homogeneous dense thin films were successfully prepared by tape casting and spin coating; however, there remains an unacceptably high difference in shrinkage rates between the film and support, which led to membrane instability. Further improvements in high pressure membrane seals also were achieved during this quarter, and a maximum pressure of 100 psig was attained. CoorsTek optimized many of the processing variables relevant to manufacturing scale production of ceramic H{sub 2} transport membranes, and SCI used their expertise to deposit a range of catalysts compositions onto ceramic membrane surfaces. Finally, MTI compiled relevant information regarding Vision 21 fossil fuel plant operation parameters, which will be used as a starting point for assessing the economics of incorporating a H{sub 2} separation unit

Advanced Hydrogen Transport Membranes for Vision 21 Fossil Fuel Plants

Eltron Research Inc. and team members CoorsTek, Sued Chemie, and Argonne National Laboratory are developing an environmentally benign, inexpensive, and efficient method for separating hydrogen from gas mixtures produced during industrial processes, such as coal gasification. This project was motivated by the National Energy Technology Laboratory (NETL) Vision 21 initiative, which seeks to economically eliminate environmental concerns associated with the use of fossil fuels. Currently, this project is focusing on four basic categories of dense membranes: (i) mixed conducting ceramic/ceramic composites, (ii) mixed conducting ceramic/metal (cermet) composites, (iii) cermets with hydrogen permeable metals, and (iv) hydrogen permeable alloys. Ultimately, these materials must enable hydrogen separation at practical rates under ambient and high-pressure conditions, without deactivation in the presence of feedstream components such as carbon dioxide, water, and sulfur. This report describes resent results for long-term hydrogen permeation and chemical stability measurements, new mixed conducting cermets, progress in cermet, thin film, and thin-walled tube fabrication, hydrogen absorption measurements for selected compositions, and membrane facilitated alkane to olefin conversion