La0.6Ca0.4Co1–xFexO3–d in its various compositions has proven to be an excellent CO2-resistant oxygen transport membrane that can be used in plasma-assisted CO2 conversion. With the goal of incorporating green hydrogen into the CO2 conversion process, this work takes a step further by investigating the compatibility of La0.6Ca0.4Co1–xFexO3–d membranes with hydrogen fed into the plasma. This will enable plasma-assisted conversion of the carbon monoxide produced in the CO2 reduction process into green fuels, like methanol. This requires the La0.6Ca0.4Co1–xFexO3–d membranes to be tolerant towards reducing conditions of hydrogen. The hydrogen tolerance of La0.6Ca0.4Co1–xFexO3–d (x = 0.8) was studied in detail. A faster and resource-efficient route based on ultrasonic spray synthesis was developed to synthesise the La0.6Ca0.4Co0.2Fe0.8O3–d membranes. The La0.6Ca0.4Co0.2Fe0.8O3–d membrane developed using ultrasonic spray synthesis showed similar performance in terms of its oxygen permeation when compared with the ones synthesised with conventional techniques, such as co-precipitation, sol–gel, etc., despite using 30% less cobalt
