Abstract: A multi-phase solid electrolyte ion transport membrane comprising at least two phases wherein one of the phases comprises an oxygen ion single conductive material. The other phase comprises an electronically-conductive metal or metal oxide conducting phase is present in a low volume percentage. One method for achieving this result incorporates the minority phase into the powder from which the membrane is made by deposition of the metal or metal oxide from a polymer made by polymerizing a chelated metal dispersion in a polymerizable organic monomer or prepolymer. The multi-phase composition advantageously comprises a first phase of a ceramic material and a second phase of a metal or metal oxide bound to a surface of the ceramic material. A second method fabricates the membrane from a mixture of two powders one of which contains a mixture of the two phases.

Abstract: Syngas, a mixture of hydrogen and carbon monoxide, is an intermediate in the conversion of methane to liquid fuels. For certain applications, it is desirable to maintain an H2/CO molar ratio of about 3. This molar ratio is achieved by steam reforming of methane in accordance with: CH4+H2O→3H2+CO. To provide the heat required to drive the endothermic steam reforming reaction, a low grade fuel is combusted in a reactor and the heat of combustion conducted to the endothermic reaction. By using an oxygen selective ion transport membrane element to transport the oxygen required for combustion, the formation of undesirable NOx compounds is minimized.

Abstract: An oxygen separator and method for separating oxygen from a heated oxygen containing gas that employs oxygen-selective ceramic membranes of elongated, tubular configuration within a duct for separation of oxygen from a heated gas. The duct can be attached between the exhaust of a gas turbine and a power generator driven by the exhaust or can be connected to one or more burners of a gas turbine. Supplementary compressed feed air may be added at a flow rate at least equal to that of the permeated oxygen for cooling and flow balancing purposes. A purge stream can also be introduced. Additionally, combustor tubes fabricated from an oxygen-selective ceramic membrane material may also be provided to produce combustion products that in turn can be used as a purge for downstream oxygen-selective ceramic membranes.

Abstract: The present invention provides an ion conducting ceramic membrane selectively permeable to a gas, for instance oxygen and a method of treating such a membrane to improve permeation through the membrane. The membrane is formed by a mass of a substance through which ions of the gas migrate. The mass has two opposed surfaces where dissociation and ionization of the gas occurs and gas ions release electrons and recombine to form molecules of the gas, respectively. At least one of said two opposed surfaces is treated by a removal of surface material to produce surface irregularities of increased area and therefore an increase in total surface area of a treated surface to in turn increase permeation of the gas. Preferably, both surfaces of the membrane are treated by chemical etching techniques, although sand blasting and ion etching are other possible surface treatments in accordance with the present invention.

Abstract: A ceramic membrane element for an oxygen separator is formed from a ceramic material represented by the structure: A1-xA′xB1-yB′yO3-z where A is a lanthanide element; A′ is a suitable lanthanide element dopant; B is selected from the group consisting of titanium, vanadium, chromium, manganese, iron, cobalt, nickel, zinc and mixtures thereof; B′ is copper; x is between 0.4 and 0.8; y is between 0.1 and 0.9; and z is>0 (and determined by stoichiometry). When B includes cobalt in an amount greater than 0.1, the included iron content is less than 0.05. The membrane element selectively transports oxygen ions therethrough at a relatively low temperature, with a flux detected at about 600° C. This enables the oxygen separator to be operated at lower temperatures than convention separators that frequently have operating temperatures in excess of 900° C. Mechanical stability may be enhanced by the addition of a second phase to the ceramic.

Abstract: A multi-phase solid electrolyte ion transport membrane comprising at least two phases wherein one of the phases comprises an oxygen ion single conductive material, or a mixed conductor. The other phase comprises an electronically-conductive metal or metal oxide that is incorporated into the membrane by deposition of the metal or metal oxide from a polymer made by polymerizing a chelated metal dispersion in a polymerizable organic monomer or prepolymer. The multi-phase composition advantageously comprises a first phase of a ceramic material and a second phase of a metal or metal oxide bound to a surface of the ceramic material. The multi-phase composition is advantageously prepared in an in-situ fashion before fabricating the membrane matrix. As another alternative, a preformed ceramic matrix is surface-coated with a metal or metal oxide.

Abstract: A method of fabricating a dense membrane by providing a colloidal suspension of a ceramic powder, and providing a polymeric precursor. The precursor is mixed together with the colloidal suspension, and the mixture is applied to a membrane support to form a composite structure. The composite structure is heated to form a dense membrane on the support.

Abstract: A process to generate an enhanced output of a desired product from an ion transport reactor utilizes the reaction products from both the cathode side and the anode side of an oxygen selective ion transport ceramic membrane. An oxygen donating first feed stream containing the desired product in a chemically bound state is delivered to the cathode side while an oxygen accepting second feed stream is delivered to the anode side. Following chemical reactions on both the cathode side and the anode side, a desired product is recovered from a first product stream exiting from the cathode side and from a second product stream exiting from the anode side such that the sum of the desired product contained within the two product streams exceeds that attainable from either product stream alone.

Abstract: A stable substantially cubic perovskite crystalline structure of at least one strontium-doped lanthanum cobalt oxide (LSC) having a stabilizing amount of at least one cerium gadolinium oxide (CGO) therein.

Abstract: A reactor comprising: a hollow shell defining a hermetic enclosure; a plurality of tube sheets disposed within said hermetic enclosure, a first one of said plurality of tube sheets defining a first chamber; at least one reaction tube each having a first end and an opposing second end, said first end being fixedly attached and substantially hermetically sealed to one end of said plurality of tube sheets and opening into said first chamber, the second end being axially unrestrained; each of said reaction tubes is comprised of an oxygen selective ion transport membrane with an anode side wherein said oxygen selective ion transport membrane is formed from a mixed conductor metal oxide that is effective for the transport of elemental oxygen at elevated temperatures and at least a portion of said first and second heat transfer sections are formed of metal; each of said reaction tubes includes first and second heat transfer sections and a reaction section, said reaction section disposed between said first and second

Abstract: A low energy cost process for the co-production of oxygen and nitrogen employing a fuel tube extending into the first oxygen selective ion transport membrane whereby fuel is introduced adjacent to the closed end and flows cocurrently with oxygen containing gas in the annulus and an oxygen selective ion transport membrane having a separator section and a reactor section. An oxygen-containing feedstock, typically air, is compressed and then contacts the cathode side of the separator section where a portion of the oxygen contained within the feedstock is transported to the anode side of the separator section and recovered as an oxygen product gas. Substantially the remainder of the oxygen contained within the feedstock is transported from the cathode side of the reactor section to the anode side and exothermically reacted with a fuel. Following the exothermic reaction, hot nitrogen rich product gas is expanded in a turbine to generate the power necessary to compress the feedstock.

Abstract: A process for separating a feed gas stream containing elemental oxygen and at least one other gas into an oxygen product gas stream having a selected concentration of oxygen, by removing the oxygen from a feed gas stream using an ion transport module containing an ion transport membrane having a retentate side and a permeate side to produce both an ultrapure oxygen gas stream emerging from the membrane into the permeate side and a retentate gas stream. The ultrapure oxygen gas stream is blended with an additive gas stream to produce an oxygen product gas stream having a selected concentration of oxygen.

Abstract: A process for inhibiting the formation of carbon and/or coke from a carbon-containing reactive gas stream on the permeate side of an oxygen ion transport membrane, or for increasing the oxygen partial pressure thereon, by separating a feed gas stream to form an oxygen-depleted gas stream on the retentate side and a gas stream containing oxygen reaction products on the permeate side. The permeate side is purged with the carbon-containing reactive gas stream, and at least a portion of the exhaust gas stream formed from the reaction of the reactive gas stream with the separated oxygen is recirculated to purge the permeate side.

Abstract: Air is separated in a double rectification column including a lower pressure rectification column. A first oxygen product containing less than 3.5% by volume of argon impurity is withdrawn through an outlet of the column which has a packed section below the level of the outlet. The argon impurity is striped from liquid descending through the packed section and a second relatively pure oxygen product containing less than 100 volumes per million is withdrawn from below the section through an outlet thereof. Impurities less volatile than oxygen are preferably separated from the second oxygen product in a side rectification column.

Abstract: A system and method for dispensing an aqueous solution to one or more points of use is provided with one or more pressure vessels that are adapted to be charged with pressurized gas to drive the aqueous solution on to the point or points of use. A humidifier is also employed to humidify the pressurized gas to at least inhibit the pressurized gas from evaporating the moisture from the aqueous solution. In such manner, changes to the make up of the aqueous solution are avoided. Such changes can produce caking and/or changes in chemical properties found in pressure vessels used in dispensing slurries.

Abstract: A product cryogenic liquid mixture comprising oxygen and nitrogen having a chosen mole fraction of oxygen is produced by expanding, typically through a valve, a pressurized stream of a precursor fluid mixture, which may be liquid air, having a mole fraction of oxygen greater than said chosen mole fraction, and thereby forming a vapor phase depleted of oxygen and a liquid phase enriched in oxygen. The vapor phase is disengaged from the liquid phase in a phase separator. A stream of the vapor phase is condensed in a condenser. The condensate is collected in a storage vessel as the product cryogenic liquid mixture.

Abstract: Ammonia is purified by a membrane unit to concentrate ammonia and/or ammonia and moisture. Moisture is removed in a temperature-swing adsorption unit. The resultant product of such purification is then partially condensed to remove light components of other impurities and then partially vaporized to produce a pressurized ammonia product lean in heavy components. If the feed stream is processed through the membrane unit first, the permeate stream will be lean in such impurities as carbon dioxide, nitrogen and methane. Moisture and any carbon dioxide not removed in the membrane unit is then removed by the adsorption unit. The resultant stream produced by action of the membrane and adsorption units is then partially condensed to produce a liquid lean in light impurities. Such liquid is then partially vaporized within a product pressure vessel to produce ammonia vapor lean in heavy impurities and at a required operational pressure.

Abstract: A liquid distributor in the form of a tray or trough network is provided with a plurality of rows of apertures through which liquid descends. A predistributor trough predistributes liquid onto the rows of apertures and is provided with bottom and side openings from which the liquid is distributed onto the plate. The side openings are located proximally with respect to the bottom openings to enhance uniformity of velocity profile of the liquid.

Abstract: Method and apparatus for smelting iron ore in which iron ore is preheated and partly reduced within a first reaction zone and then further reduced in a second reaction zone. The first reaction zone can be a shaft reduction furnace and the second reaction zone can be a melter gasifier. An auxiliary third reaction zone partially oxidizes a carbonaceous material to produce char for the third reaction zone. A reducing gas produced by partial oxidation of the char is used to effect the partial reduction conducted within the first reaction zone. Volatile substances contained within a heating gas produced by the partial oxidation within the auxiliary third reaction zone is further oxidized and used to preheat the iron ore within the first reaction zone.

Abstract: A valve manifold box system and method in which one or more dispense units dispense chemical to a plurality points of use. A fluid circuit is provided with valve manifolds connected in series by double walled conduits known as containment pipes. The fluid circuit is either in the form of a loop of a series of valve manifolds alternating with double walled piping so that each valve manifold is fed with chemical at opposite ends. Alternately, two dispense units could be connected to the end of an in-line type of fluid circuit. The valve manifolds are contained within valve boxes and the ends of the containment pipes are connected to the valve boxes. In this manner a leak in either the valve manifolds or the containment pipes collects within the valve boxes. Leak detectors are provided in the valve boxes and upon the sensing of a leak, the potentially leaking valve manifold as well as the associated, adjacent containment pipes feeding such valve manifold are isolated by isolation valves.