Supported Flat Plate Thin Films for Oxygen Separation--Eltron Research, Inc., 4600 Airport Blvd., Boulder, CO 80301-3241; 303-530-0236
Dr. Richard Mackay, Principal Investigator
Ms. Eileen E. Sammells, Business Official
DOE Grant No. DE-FG03-99ER82783
Amount: $749,922

Wide spread commercial production of fuels or chemicals from synthesis gas has been hindered by the high cost of producing oxygen, which is required for either the gasification of coal or the reforming of natural gas. Membrane processes for oxygen separation have shown potential, but polymeric membranes suffer from low selectivity, while ceramic membranes require high temperature to increase flux rate. In previous work, ceramic mixed ionic and electronic conductors were developed that exhibit high oxygen flux when placed in catalytic membrane reactors. These flux rates could be further increased by decreasing membrane thickness. Therefore, this project will develop an economical process for fabricating the ceramic membranes as thin films. Phase I developed a method for coating mixed polymer/powder precursors onto a porous substrate. The precursor decomposed and sintered to full density. The thin films were tested in reactors and demonstrated increased flux relative to thick membranes. Phase II will focus on the necessary processes for optimal reactor operation. Improved coating procedures for thin films will be developed and substrates with higher porosity will be fabricated. The performance of the catalyst will be optimized.

Commercial Applications and Other Benefits as described by the awardee: A quick, reliable, and inexpensive method of making ceramic thin films capable of separating oxygen from air should find use in applications requiring a source of pure oxygen. In combustion processes, for example, the use of pure oxygen will increase heating efficiency by the removal of the N₂ diluent, with simultaneous reduction in NO_x emissions.