Optimization of mixed conducting perovskites for the application in dense ceramic oxygen separation membranes, used in partial oxidation of natural gas to synthesis gas

The aim in this project was the optimization of LaFeO3-based perovskite materials for oxygen separation membranes (OSM). The work was carried out by the Laboratory for High Performance Ceramics, Empa in collaboration with the Laboratory for Industrial Energy Systems, LENI, EPFL and the Ceramics Laboratory, LC, EPFL. The ceramic material of interest is a mixed conductor for oxygen ions and electrons at high temperature (800°-900°C) and therefore can separate oxygen from nitrogen with 100% selectivity when exposed to an oxygen partial pressure gradient (e.g. air vs. natural gas). In this capacity, such materials are attractive for the application of partial oxidation (POX) of natural gas (NG) to synthesis gas in an important and growing business. The crucial point in this developing technology is the chemical and mechanical stability of the membrane under the operating conditions (high temperature, PO2 gradient). Because of thermal and chemical expansion, large stress can be induced in the material, which can lead to fracturing. Additional destabilizing processes such as kinetic demixing (elemental segregation under influence of the oxygen gradient) or slow phase transformation can lead to decreased performance with time. The overall goal in this Ph.D. thesis was to address these stability problems from a combined experimental and theoretical point of view in order to develop a more detailed understanding and strategy for improving the materials properties. Experimentally, the ceramic membrane materials were synthesized with different B-site substitutions with the aim of decreasing chemical expansion. The focus lied on LaFeO3 materials substituted with Sr on A-site. Detailed characterizations of the most promising compositions were done including structural, transport, and mechanical properties.

La0.5Sr0.5Fe1-yMyO3-[delta] (M = Ti, Ta) perovskite oxides for oxygen separation membranes

Defne Bayraktar

Mixed ionic electronic conducting perovskite materials have been receiving considerable attention for the application of oxygen separation membranes. These membranes have potential to be integrated in industrial processes that require pure oxygen and to provide advantages considering economical and environmental aspects. The used perovskite materials can accommodate a high concentration of disordered oxygen vacancies and provide high oxygen permeation flux in the presence of an oxygen partial pressure gradient. However, the materials with high oxygen flux are observed to have low chemical and mechanical stability, originating from oxygen vacancy formation and reduction of the B-site transition metal ion. Based on the fact that the stability of the materials at reducing pO2 is dependent on the redox stability of the B-site cation, a partial substitution of the B-site transition metal with a more stable cation is considered in this thesis to improve the stability of the base perovskite oxide. The approach used for the identification of the suitable material based on the host composition La0.5Sr0.5FeO3-δ (LSF) was to first explore the B-site substituting elements in terms of their effect on the thermal expansion and the isothermal expansion measured during the atmosphere change from air to argon. The elements Al, Cr, Zr, Ga, Ti, Sn, Ta, In, V, and Mg were used for 10 or 20% substitution of Fe. The isothermal expansion of the host material was decreased by substitution, which was attributed to decreased amount of oxygen vacancy formation as it was evidenced later by TGA of chosen compositions. As a result, the compositions substituted with higher valence ions (particularly, 20% Ti4+, LSFTi2, and 10% Ta5+, LSFTa1) were identified as the least expanding materials in isothermal conditions. The effect of substitution was further characterized extensively including structural, mechanical, and oxygen transport properties. The oxygen vacancy (VO••) concentration changes induced by substitution of Fe were reflected in unit cell sizes of heat-treated samples under argon atmosphere. The increase in the unit cell size was attributed to the isothermal expansion due to B-site reduction and lowered to half in case of substituted LSFTi2 and LSFTa1 compared to the host material LSF. Similar trends were observed for interrelated properties such as the coefficient of thermal expansion, isothermal expansion, and the actual amount of oxygen vacancies formed under argon at 900°C, all of which were higher for LSF. The mechanical properties of LSF, LSFTi2, and LSFTa1 were characterized at room temperature. The Young's modulus and the bending strength of the materials were in the same range (141-147 GPa and ∼120 MPa, respectively) while the fracture toughness of the LSF sample was improved by Ti and especially Ta substitution. The fractography of the samples provided evidence that the several LSF samples showed extended cracks possibly related to residual stresses forming during cooling, due to non-equilibrated oxygen stoichiometry across the sample. The potential step measurements showed that the chemical diffusion and the surface exchange coefficients measured during oxidation of the samples were higher than the ones measured during reduction of the samples. The tendency was reversed at lowered pO2 along with the decrease of both coefficients. The influence of B-site substitution on both coefficients was not substantial. The oxygen permeation flux of LSF, LSFTi2, and LSFTa1 was measured under air/argon gradient on planar membranes. The permeation rates of the membranes with thicknesses close to 1 mm were considered to be limited by surface exchange kinetics at temperatures above 875°C. The permeation rate of LSF was decreased (from 0.2 µmolcm-2s-1) to its third by Ti and Ta additions. The permeation rate of Ti and Ta-substituted samples showed a drop around 875°C, keeping a similar activation energy at lower and higher temperature regions. Oxygen vacancy ordering in the perovskite structure was given as a possible explanation, which provided explanation for the slow equilibrium in the lower temperature region. Tubular membranes of LSF and LSFTi2 (0.47 mm and 0.36 mm thick, respectively) and a planar LSFTa1 membrane were characterized using an air/(Ar-CH4) gradient. The measurements conducted using pure Ar on the lean-side provided the possibility to compare the thickness dependence of the permeation. In agreement with the previous observations, the permeation of the materials at and above 900°C was independent of the thickness, therefore, surface exchange limited. Stability under reducing atmospheres was increased by substitution. The LSF membrane failed shortly after the introduction of CH4 to the system, while LSFTi2 survived 5% CH4 and its oxygen permeation was improved substantially by a factor of 14. LSFTa1 membrane was measured with pure CH4 and the permeation was increased by a factor of 9, reaching 0.7 µmolcm-2s-1 at 900°C. The membrane operated stably over 2000h with pure CH4, 1000h. A slow degradation of 3.7% per 1000h was observed at 1000°C, most probably due to cation migration. The compositions identified as a result of B-site substitution screening were effective in improving the stability of the materials without extensive loss of the oxygen permeation rate. Ta-substituted material was shown to be promising with its long-term stability as a partial oxidation membrane.

EPFL2008

Improved stability of La0.5Sr0.5FeO3 by Ta-doping for oxygen separation membrane application

Defne Bayraktar, Stefan Diethelm, Jan Van Herle

(La,Sr)FeO3 mixed conducting perovskites are considered as interesting candidates for oxygen separation membranes but they suffer from limited structural stability in a large oxygen partial pressure (pO2) gradient, because of their propensity for chemical expansion. Partial substitution of Fe with more stable elements tends to improve the stability while penalizing the electronic and ionic conductivities. In this study, we investigate the effect of 10% Ta substitution on the oxygen transport properties and stability of La0.5Sr0.5FeO3. For this purpose, the material was evaluated as a membrane in a CPOX reactor. The oxygen permeation through a ~ 3 cm2 pellet sample was first measured under air/Ar gradient in the temperature range of 800 to 1000 °C. The measured flux was 0.1 µmol cm− 2 s− 1 at 900 °C, which was a factor of 2 lower than for the Ta-free material. Methane was then introduced into the system and reacted in a catalytic bed with oxygen that has permeated through the membrane to form syngas (H2, CO). As a result, the oxygen flux increased by a factor of 9, reaching 0.9 µmol cm− 2 s− 1 at 900 °C. The reactor was operated at 1000 °C for another 1000 h. During this time, the oxygen permeation flux decayed by ca. 4%/1000 h. The test was stopped after more than 2000 h of operation and the membrane analyzed by electron microscopy.

2009

Préparation et caractérisation de nanoparticules bimétalliques (Pt-Au) sur un substrat en diamant dopé au bore

Bahaa El Roustom

Using petrol as a main source of energy, during the 20th century, has caused considerable amounts of damage among which are atmospheric pollution and global warming. At the same time, many geologists and economists expect that the discovery rate of new petrol sources will not follow the market's demand causing a serious shortage of petrol in the near future. These alarming perspectives have motivated scientists around the world to develop new clean and renewable energy sources. It is in that objective that electrochemists intensified their research in order to develop the fuel cell technology. This latter consists in directly converting chemical energy into electricity. The main advantage of this technology over traditional energy production is that the fuel cell energy efficiency is Carnot cycle independent. The theoretical efficiency of such an energy source is nearly 90%. Direct Alcohol Fuel Cell (DAFC), fed by ethanol on one hand and by air (oxygen) in the other hand, is a very interesting option for such kind of energy production. Ethanol is a renewable energy source of vegetal origin whose CO2 production is consumed by plants during the cycle. Even though Pt has long been known to be a perfect catalyst for DAFC, it has some principal limitations, the most important ones being poisoning by intermediate products (OH on the cathodic side and CO on the anodic side) and a relatively high cost compared to other materials. These problems have pushed the experts in the field to focalize their research on the development of more suitable and better performing materials. Gold nanoparticles have shown a surprising catalytic activity, very different from the bulk, making them a preferential candidate to replace Pt. A system based on using two or more metals as catalysts (example Au-Pt) dispersed on an appropriate substrate seems to be also an interesting candidate to enhance the cell's efficiency. The substrate should be chemically inert, non-oxydable and should not present any interference with the electrochemical and electrocatalytic behaviour of the nanoparticles. In the first part, the employed substrate, which is boron doped diamond (BDD) is characterized. The substrate's main characteristics are its chemical inertness, its weak residual current and its resistance to corrosion. These characteristics contribute to making the substrate an ideal support for nanoparticles. In this work, the substrate is a diamond film, but for fuel cell applications diamond should be used as powder or dispersed particles. In chapters III and IV, we studied the effect of boron incorporation on the morphology and the behaviour of the diamond film. For this purpose, samples with different ratios of boron/carbon (B/C) in the vapour phase during preparation were characterized (B/C = 300, 1000, 2500 and 6000 ppm). Results showed that the grain size decreases with increasing boron content in the film. This is accompanied by a transition towards a quasi-metallic character. It was also found that graphitic impurities in the diamond film increase when the B/C ratio increases. We also established some graphitic impurities increase in the diamond film when the ratio of B/C increases. The identity of these impurities was established in chapter III as being surface redox couples (semi-quinone/semi-hydroquinone). Using cyclic voltametry we were able to observe a total elimination (B/C=300 ppm) or partial elimination (B/C=6000 ppm) of these surface redox couples. We also found in chapter IV that these surface redox couples are responsible of the electrochemical activity of the BDD electrode. BDD electrodes with different doping level B/C=300, 1000 and 6000 ppm) in the vapour phase are modified with IrO2 nanoparticles using the method of thermal decomposition. Our results showed that, at low potentials, the behaviour of the composite electrode IrO2/BDD with respect to the reaction of oxygen evolution is independent of the doping level. On the other hand, at high potentials, the weakly doped electrode (B/C=300 ppm) presents a supplementary overpotential due to the interface BDD-IrO2. An approach based on the double junction is developed in this work describing two distinct behaviours depending on the boron concentration in the diamond film. A new method for Au nanoparticles deposition on highly doped BDD electrodes (B/C= 2500 ppm) is presented in chapter VI. This method involves two steps: the first step consists on sputtering the equivalent of few nanolayers of Au on the diamond surface; the second step is a heat treatment in air at high temperatures. Several parameters that could influence the dispersion, the stability as well as the diameter of the Au nanoparticles are studied. In chapter VII, the behaviour of the composite electrode Au/BDD is studied in a solution containing redox couples in acid media. This electrode was simulated as an arrangement of active Au microelectrodes dispersed on a less active BDD substrate. The overall behaviour of the composite electrode (Au/BDD) has been related to the electrochemical rate constants on each material. In chapter VIII, another new synthesis method for a bimetallic system formed by Au and Pt nanoparticles dispersed on a BDD substrate is developed. This method consists in electrodepositing a small amount of Pt on a composite electrode Au/BDD. Our results showed that Pt was preferentially deposited on Au covering its whole surface. In fact, Au nanoparticles serve as germ of nucleation for Pt. In the following step, the bimetallic PtbAu/BDD is heated to 400°C in air to enhance the interaction between Au and Pt. The experiments showed that Au reappeared on the surface. The electrochemical behaviour of the bi-metallic electrode is characterized by a negative shift in the peak potential of reduction of Pt oxides. This is not the case of heterogeneous alloys obtained by the fusion of two metals at high temperatures. The composite electrode Au/BDD as well as the bi-metallic electrode Pt-Au/BDD are used for electrocatalytic applications. The studied reaction in chapter IX is the oxygen reduction reaction (ORR) in an acid medium. We found that the number of exchanged electrons increases with increasing the amount of Pt at the surface. Oxygen is reduced into H2O2 on the Au/BDD electrode and into H2O on the Pt-Au/BDD electrode. In chapter X we studied the reaction of oxidation of oxalic acid. The behaviour of both Au and Pt electrodes seemed very similar for this reaction. The bi-metallic electrode containing both Pt and Au on its surface has shown an intermediate behaviour between the behaviour of the two metals.