The Standard Oil Company

Technology Management, Inc.

Other

United States of America as Represented by the Administrator of Nasa

Bp Corporation North America Inc.

Praxair Technology, Inc.

Volt Research, LLC

Sfco-Efs Holdings, LLC

Thomas L Cable

Terry Joseph Mazanec

John G Frye, Jr

Wayne R Kliewer

Michael A Petrik

Ravi Prasad

Christian Friedrich Gottzmann

Joseph Michael Schwartz

Victor Emmanuel Bergsten

James Eric White

John C Fagley

Stephen W Sofie

Benson P Lee

Ajit Sane

Robert C Ruhl

Kurt E Kneidel

Christopher E Milliken

Serene Farmer

Eric A Barringer

John A Setlock

Adam B Brakas

Terry I Mazanec

Thomas C Yuan

A membrane for use in a high temperature gas processing system and method for making the same. The membrane includes a dense, gas impermeable layer and a first and second porous layer, wherein each of the first and second porous layers is a ceramic oxide material having a non-symmetrical load bearing skeleton of a plurality of pores having a graded porosity. Each porous layer provides a reduction of an oxygen partial pressure gradient across the dense layer and reduces resultant stresses in the dense layer that are small compared to its strength thereby improving long term mechanical durability of the dense layer.

High temperature gas processing system and method for making the same

The invention is a novel solid oxide fuel cell (SOFC) stack comprising individual bi-electrode supported fuel cells in which an electrolyte layer is supported between porous electrodes. The porous electrodes may be made from graded pore ceramic tape that has been created by the freeze cast method followed by freeze-drying. Each piece of graded pore tape later becomes a graded pore electrode scaffold that, subsequent to sintering, is made into either an anode or a cathode. The electrode scaffold comprising the anode includes a layer of liquid metal. The pores of the electrode scaffolds gradually increase in diameter as the layer extends away from the electrolyte layer. As a result of this diameter increase, any forces that would tend to pull the liquid metal away from the electrolyte are reduced while maintaining a diffusion path for the fuel. Advantageously, the fuel cell of the invention may utilize a hydrocarbon fuel without pre-processing to remove sulfur.

Method for making a fuel cell

The invention is a novel solid oxide fuel cell (SOFC) stack comprising individual bi-electrode supported fuel cells in which a thin electrolyte is supported between electrodes of essentially equal thickness. Individual cell units are made from graded pore ceramic tape that has been created by the freeze cast method followed by freeze drying. Each piece of graded pore tape later becomes a graded pore electrode scaffold that subsequent to sintering, is made into either an anode or a cathode by means of appropriate solution and thermal treatment means. Each cell unit is assembled by depositing of a thin coating of ion conducting ceramic material upon the side of each of two pieces of tape surface having the smallest pore openings, and then mating the coated surfaces to create an unsintered electrode scaffold pair sandwiching an electrolyte layer. The opposing major outer exposed surfaces of each cell unit is given a thin coating of electrically conductive ceramic, and multiple cell units are stacked, or built up by stacking of individual cell layers, to create an unsintered fuel cell stack. Ceramic or glass edge seals are installed to create flow channels for fuel and air. The cell stack with edge sealants is then sintered into a ceramic monolithic framework. Said solution and thermal treatments means convert the electrode scaffolds into anodes and cathodes. The thin layers of electrically conductive ceramic become the interconnects in the assembled stack.

Method for making a fuel cell from a solid oxide monolithic framework

The present invention is a symmetrical bi-electrode supported solid oxide fuel cell comprising a sintered monolithic framework having graded pore electrode scaffolds that, upon treatment with metal solutions and heat subsequent to sintering, acquire respective anodic and cathodic catalytic activity. The invention is also a method for making such a solid oxide fuel cell. The graded pore structure of the graded pore electrode scaffolds in achieved by a novel freeze casting for YSZ tape.

Symmetrical, bi-electrode supported solid oxide fuel cell

Solid membranes comprising an intimate, gas-impervious, multi-phase mixture of an electronically-conductive material and an oxygen ion-conductive material and/or a mixed metal oxide of a perovskite structure are described. Electrochemical reactor components, such as reactor cells, and electrochemical reactors are also described for transporting oxygen from any oxygen-containing gas to any gas or mixture of gases that consume oxygen. The reactor cells generally comprise first and second zones separated by an element having a first surface capable of reducing oxygen to oxygen ions, a second surface capable of reacting oxygen ions with an oxygen-consuming gas, an electron-conductive path between the first and second surfaces and an oxygen ion-conductive path between the first and second surfaces. The element may further comprise (1) a porous substrate, (2) an electron-conductive metal, metal oxide or mixture thereof and/or (3) a catalyst. The reactor cell may further comprise a catalyst in the zone which comprises a passageway from an entrance end to an exit end of the element. Processes described which may be conducted with the disclosed reactor cells and reactors include, for example, the partial oxidation of methane to produce unsaturated compounds or synthesis gas, the partial oxidation of ethanes substitution of aromatic compounds, extraction of oxygen from oxygen-containing gases, including oxidized gases, ammoxidation of methane, etc. The extraction of oxygen from oxidized gases may be used for flue or exhaust gas cleanup.

Solid multi-component membranes, electrochemical reactor components, electrochemical reactors and use of membranes, reactor components, and reactor for oxidation reactions

A method, apparatus and assembly related to solid oxide fuel cell interconnects is disclosed. In its broadest embodiment, the invention contemplates a multi-layered ceramic interconnect having integrated flow fields and electrical connections. The method of making this interconnect includes judicious selection of materials, formation of appropriate apertures for the flow fields and electrical connectors, and the joining of the layers through a firing and/or sealing process.

High performance ceramic fuel cell interconnect with integrated flowpaths and method for making same

The invention relates to a process for the separation of oxygen from an oxygen-containing fluid using novel membranes, formed from perovskitic or multi-phase structures, with a chemically active coating. The process exhibits exceptionally high rates of oxygen flux. The process uses membranes that are conductors of oxygen ions and electrons, which are substantially stable in air over the temperature range of 25&deg; C. to the operating temperature of the membrane.

Oxygen separation process

The invention relates to a process for the production of oxygen using novel membranes, formed from perovskitic or multi-phase structures, with a chemically active coating which demonstrate exceptionally high rates of fluid flux. The process uses membranes that are conductors of oxygen ions and electrons, which are substantially stable in air over the temperature range of 25&deg; C. to the operating temperature of the membrane.

Oxygen production process

An exothermic reaction and an endothermic reaction are thermally combined in a reactor having at least one oxygen selective ion transport membrane that provides the exothermic reaction with oxygen from an oxygen-containing gas such as air. The thermal requirements of the endothermic reaction are satisfied by the exothermic reaction. Dependent on the reactor design employed, the exothermic and endothermic reactions may be gaseously combined.

Process for producing a syngas

Electrochemical processes using solid gas-impervious membranes are disclosed for gas cleanup by (A) providing an electrochemical cell comprising first and second zones separated by a solid gas-impervious membrane comprising a mixed metal oxide material of a perovskite structure having electron conductivity and oxygen ion conductivity, (B) passing a gas containing N,O, NO, NO,, SO,, SO,, or a mixture thereof, in contact with the membrane in the first zone, and (C) passing a gas capable of reacting with oxygen in contact with the membrane in the second zone. More particularly, the mixed metal oxide material of a perovskite structure comprises a combination of elements selected from the group consisting of lanthanides, alkaline earth metals, Y, Sc, Ti, V, Cr, Mn, Fe, Co, Ni, Cu, Zn, Zr, and Nb, oxides thereof, and mixtures of these metals and metal oxides. Advantageously a catalyst is present in the first zone.

Solid membranes comprising an intimate, gas-impervious, multi-phase mixture of an electronically-conductive material and an oxygen ion-conductive material and/or a mixed metal oxide of a perovskite structure are described. Electrochemical reactor components, such as reactor cells, and electrochemical reactors are also described. The reactor cells generally comprise first and second zones separated by an element having a first surface capable of reducing oxygen to oxygen ions, a second surface capable of reacting oxygen ions with an oxygen-consuming gas, an electron-conductive path between the first and second surfaces and an oxygen ion-conductive path between the first and second surfaces.

A process and apparatus for steam reforming of hydrocarbons, using a sulfur-tolerant catalyst comprising an active phase and a support phase, and optionally a promoter, which provides substantially complete conversion of the hydrocarbon to a mixture of hydrogen, carbon monoxide, and carbon dioxide. The process comprises introducing steam and a hydrocarbon feed containing at least about 2 ppm sulfur species into the apparatus, and reacting said steam and hydrocarbon feed in the catalyst bed.

Method for steam reforming hydrocarbons using a sulfur-tolerant catalyst

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 heat transfer sections; a reforming catalyst disposed about said anode side of said oxygen selective ion transport membrane; a first process gas inlet; a second process gas inlet; and, a plurality of outlets.

Tube and shell reactor with oxygen selective ion transport ceramic

An electrochemical process for extracting oxygen from an oxygen-containing gas which uses an electrochemical cell having two zones separated by a multi-component membrane made from intimate, gas-impervious, multi-phase mixture of an electronically conductive phase and an oxygen ion-conducting phase. In one zone a gas containing oxygen is passed in contact with the membrane. In the other zone a gas capable of reacting with oxygen is passed in contact with the membrane.

Solid multi-component membranes, electrochemical reactor components,

An article for the separation, storage and delivery of substantially pure oxygen, comprises a closed walled, hollow container wherein at least a portion of at least one wall of the container is an oxygen separation material, providing a sole means for transporting substantially all oxygen into the container. An apparatus for the delivery of oxygen comprises means for transferring oxygen from a fluid containing oxygen to at least one such container at elevated temperature and pressure. The apparatus can provide means for transporting said the substantially pure oxygen-bearing container, means for storing said the container, and means for extracting oxygen from the container. A process includes filling the article with substantially pure oxygen, and, storing the substantially pure oxygen within the container for a selected period of time. The process may include releasing the oxygen from the container. The process may be used for the purification of oxygen, or the purification of a fluid containing oxygen as an impurity.

Growing community of inventors

Newbury, OH, United States of America

Thomas L Cable