Abstract: A method is described of producing a catalyst-containing composite oxygen ion membrane and a catalyst-containing composite oxygen ion membrane in which a porous fuel oxidation layer and a dense separation layer and optionally, a porous surface exchange layer are formed on a porous support from mixtures of (Ln1?xAx)wCr1?yByO3?? and a doped zirconia. Adding certain catalyst metals into the fuel oxidation layer not only enhances the initial oxygen flux, but also reduces the degradation rate of the oxygen flux over long-term operation. One of the possible reasons for the improved flux and stability is that the addition of the catalyst metal reduces the chemical reaction between the (Ln1?xAx)wCr1?yByO3?? and the zirconia phases during membrane fabrication and operation, as indicated by the X-ray diffraction results.

Abstract: A method is described of producing a catalyst-containing composite oxygen ion membrane and a catalyst-containing composite oxygen ion membrane in which a porous fuel oxidation layer and a dense separation layer and optionally, a porous surface exchange layer are formed on a porous support from mixtures of (Ln1?xAx)wCr1?yByO3?? and a doped zirconia. Adding certain catalyst metals into the fuel oxidation layer not only enhances the initial oxygen flux, but also reduces the degradation rate of the oxygen flux over long-term operation. One of the possible reasons for the improved flux and stability is that the addition of the catalyst metal reduces the chemical reaction between the (Ln1?xAx)wCr1?yByO3?? and the zirconia phases during membrane fabrication and operation, as indicated by the X-ray diffraction results.

Abstract: This invention relates to highly active and stable catalyst composite used in high temperature synthesis gas production. More specifically, nickel alumina catalysts doped with noble metals and lanthanide groups or transition metal groups containing a lattice spinel structure with a general formula [NixA1-x][(ByAl1-y)2]O4. Stabilizers such as yttria-stabilized zirconia are also integrated in this composite to enhance high temperature catalytic performance. The catalyst composite of present invention exhibits high redox tolerance, coking resistance, high temperature stability, and high catalytic activity.

Abstract: This invention relates to highly active and stable catalyst composite used in high temperature synthesis gas production. More specifically, nickel alumina catalysts doped with noble metals and lanthanide groups or transition metal groups containing a lattice spinel structure with a general formula [NixA1-x] [(ByAl1-y)2]O4 Stabilizers such as yttria-stabilized zirconia are also integrated in this composite to enhance high temperature catalytic performance. The catalyst composite of present invention exhibits high redox tolerance, coking resistance, high temperature stability, and high catalytic activity.

Abstract: The invention relates to a commercially viable modular ceramic oxygen transport membrane system for utilizing heat generated in reactively-driven oxygen transport membrane tubes to generate steam, heat process fluid and/or provide energy to carry out endothermic chemical reactions. The system provides for improved thermal coupling of oxygen transport membrane tubes to steam generation tubes or process heater tubes or reactor tubes for efficient and effective radiant heat transfer.

Abstract: A composite oxygen transport membrane having a dense layer, a porous support layer and an intermediate porous layer located between the dense layer and the porous support layer. Both the dense layer and the intermediate porous layer are formed from an ionic conductive material to conduct oxygen ions and an electrically conductive material to conduct electrons. The porous support layer has a high permeability, high porosity, and a microstructure exhibiting substantially uniform pore size distribution as a result of using PMMA pore forming materials or a bi-modal particle size distribution of the porous support layer materials. Catalyst particles selected to promote oxidation of a combustible substance are located in the intermediate porous layer and in the porous support adjacent to the intermediate porous layer. The catalyst particles can be formed by wicking a solution of catalyst precursors through the porous support toward the intermediate porous layer.

Abstract: A method of producing a composite oxygen ion membrane and a composite oxygen ion membrane in which a porous fuel oxidation layer and a dense separation layer and optionally, a porous surface exchange layer are formed on a porous support from mixtures of (Ln1-xAx)wCr1-yByO3-? and a doped zirconia. In the porous fuel oxidation layer and the optional porous surface exchange layer, A is Calcium and in the dense separation layer A is not Calcium and, preferably is Strontium. Preferred materials are (La0.8Ca0.2)0.95Cr0.5Mn0.5O3-? for the porous fuel oxidation and optional porous surface exchange layers and (La0.8Sr0.2)0.95Cr0.5Fe0.5O3-? for the dense separation layer. The use of such materials allows the membrane to sintered in air and without the use of pore formers to reduce membrane manufacturing costs. The use of materials, as described herein, for forming the porous layers have application for forming any type of porous structure, such as a catalyst support.

Abstract: A method and apparatus for producing a carbon monoxide containing product in which cathode and anode sides of an electrically driven oxygen separation device are contacted with carbon dioxide and a reducing agent, respectively. The carbon dioxide is reduced to carbon monoxide through ionization of oxygen and the reducing agent lowers the partial pressure of oxygen at the anode side to partially drive oxygen ion transport within the device through the consumption of the oxygen and to supply heat. The lowering of oxygen partial pressure reduces voltage and therefore, electrical power required to be applied to the device and the heat is supplied to heat the device to an operational temperature and to the reduction of the carbon dioxide occurring at the cathode side. The device can be used as part of an integrated apparatus in which the carbon dioxide is supplied from a waste stream of a process plant.

Abstract: The invention relates to a commercially viable modular ceramic oxygen transport membrane reforming reactor configured using repeating assemblies of oxygen transport membrane tubes and catalytic reforming reactors.

Abstract: A commercially viable modular ceramic oxygen transport membrane reforming reactor for producing a synthesis gas that improves the thermal coupling of reactively-driven oxygen transport membrane tubes and catalyst reforming tubes required to efficiently and effectively produce synthesis gas.

Abstract: A method and apparatus for producing heat used in a synthesis gas production process is provided. The disclosed method and apparatus include a plurality of tubular oxygen transport membrane elements adapted to separate oxygen from an oxygen containing stream contacting the retentate side of the membrane elements. The permeated oxygen is combusted with a hydrogen containing synthesis gas stream contacting the permeate side of the tubular oxygen transport membrane elements thereby generating a reaction product stream and radiant heat. The present method and apparatus also includes at least one catalytic reactor containing a catalyst to promote the steam reforming reaction wherein the catalytic reactor is surrounded by the plurality of tubular oxygen transport membrane elements. The view factor between the catalytic reactor and the plurality of tubular oxygen transport membrane elements radiating heat to the catalytic reactor is greater than or equal to 0.5.

Abstract: A method and apparatus for producing a synthesis gas product having one or more oxygen transport membrane elements thermally coupled to one or more catalytic reactors such that heat generated from the oxygen transport membrane element supplies endothermic heating requirements for steam methane reforming reactions occurring within the catalytic reactor through radiation and convention heat transfer. A hydrogen containing stream containing no more than 20 percent methane is combusted within the oxygen transport membrane element to produce the heat and a heated combustion product stream. The heated combustion product stream is combined with a reactant stream to form a combined stream that is subjected to the reforming within the catalytic reactor. The apparatus may include modules in which tubular membrane elements surround a central reactor tube.

Abstract: The invention relates to a commercially viable modular ceramic oxygen transport membrane reforming reactor configured using repeating assemblies of oxygen transport membrane tubes and catalytic reforming reactors.

Abstract: The invention relates to a commercially viable modular ceramic oxygen transport membrane system for utilizing heat generated in reactively-driven oxygen transport membrane tubes to generate steam, heat process fluid and/or provide energy to carry out endothermic chemical reactions. The system provides for improved thermal coupling of oxygen transport membrane tubes to steam generation tubes or process heater tubes or reactor tubes for efficient and effective radiant heat transfer.

Abstract: A commercially viable modular ceramic oxygen transport membrane reforming reactor for producing a synthesis gas that improves the thermal coupling of reactively-driven oxygen transport membrane tubes and catalyst reforming tubes required to efficiently and effectively produce synthesis gas.

Abstract: A method of producing a composite oxygen ion membrane and a composite oxygen ion membrane in which a porous fuel oxidation layer and a dense separation layer and optionally, a porous surface exchange layer are formed on a porous support from mixtures of (Ln1-xAx)wCr1-yByO3-? and a doped zirconia. In the porous fuel oxidation layer and the optional porous surface exchange layer, A is Calcium and in the dense separation layer A is not Calcium and, preferably is Strontium. Preferred materials are (La0.8Ca0.2)0.95Cr0.5Mn0.5O3-? for the porous fuel oxidation and optional porous surface exchange layers and (La0.8Sr0.2)0.95Cr0.5Fe0.5O3-? for the dense separation layer. The use of such materials allows the membrane to sintered in air and without the use of pore formers to reduce membrane manufacturing costs. The use of materials, as described herein, for forming the porous layers have application for forming any type of porous structure, such as a catalyst support.

Abstract: An oxygen transport membrane assembly having a coating or overlay system is provided. The overlay or coating system is disposed on the one or more surfaces of the metal containing components within the oxygen transport membrane assembly and comprises a plurality of protective layers providing oxidation resistance, chromium diffusion barrier and high emissivity. The disclosed overlay or coating system may include at least one layer of an aluminum oxide or magnesium-aluminum oxide to provide an effective oxidation resistance and/or chromium diffusion barrier. In addition, the overlay or coating system includes a high emissivity layer such as a high porosity ceramic-oxide layer or an aluminum-phosphate layer including a plurality of carbon encapsulated within the aluminum-phosphate matrix.

Abstract: A method of producing a composite oxygen ion membrane and a composite oxygen ion membrane in which a porous fuel oxidation layer and a dense separation layer and optionally, a porous surface exchange layer are formed on a porous support from mixtures of (Ln1-xAx)wCr1-yByO3-? and a doped zirconia. In the porous fuel oxidation layer and the optional porous surface exchange layer, A is Calcium and in the dense separation layer A is not Calcium and, preferably is Strontium. Preferred materials are (La0.8Ca0.2)0.95Cr0.5Mn0.5O3-? for the porous fuel oxidation and optional porous surface exchange layers and (La0.8Sr0.2)0.95Cr0.5Fe0.5O3-? for the dense separation layer. The use of such materials allows the membrane to sintered in air and without the use of pore formers to reduce membrane manufacturing costs. The use of materials, as described herein, for forming the porous layers have application for forming any type of porous structure, such as a catalyst support.

Abstract: A method and apparatus for producing heat used in a synthesis gas production process is provided. The disclosed method and apparatus include a plurality of tubular oxygen transport membrane elements adapted to separate oxygen from an oxygen containing stream contacting the retentate side of the membrane elements. The permeated oxygen is combusted with a hydrogen containing synthesis gas stream contacting the permeate side of the tubular oxygen transport membrane elements thereby generating a reaction product stream and radiant heat. The present method and apparatus also includes at least one catalytic reactor containing a catalyst to promote the steam reforming reaction wherein the catalytic reactor is surrounded by the plurality of tubular oxygen transport membrane elements. The view factor between the catalytic reactor and the plurality of tubular oxygen transport membrane elements radiating heat to the catalytic reactor is greater than or equal to 0.5.

Abstract: A method and apparatus for producing a carbon monoxide containing product in which cathode and anode sides of an electrically driven oxygen separation device are contacted with carbon dioxide and a reducing agent, respectively. The carbon dioxide is reduced to carbon monoxide through ionization of oxygen and the reducing agent lowers the partial pressure of oxygen at the anode side to partially drive oxygen ion transport within the device through the consumption of the oxygen and to supply heat. The lowering of oxygen partial pressure reduces voltage and therefore, electrical power required to be applied to the device and the heat is supplied to heat the device to an operational temperature and to the reduction of the carbon dioxide occurring at the cathode side. The device can be used as part of an integrated apparatus in which the carbon dioxide is supplied from a waste stream of a process plant.