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Journal of Membrane Science 288 (2007) 175–187

Air separation using a catalytically modified mixed


conducting ceramic hollow fibre membrane module
Alan Thursfield, Ian S. Metcalfe ∗
School of Chemical Engineering and Advanced Materials, University of Newcastle upon Tyne, Newcastle upon Tyne NE1 7RU, United Kingdom
Received 7 September 2006; received in revised form 8 November 2006; accepted 10 November 2006
Available online 21 November 2006

Abstract
A membrane reactor module consisting of four gas-tight hollow fibre membranes made of the mixed ionic-electronic conducting perovskite
La0.6 Sr0.4 Co0.2 Fe0.8 O3 − δ has been tested for oxygen permeation in the temperature range of 650–1000 ◦ C with air on one side and helium on the
other. The module was operated under gradientless gas-phase conditions and in the absence of mass transfer limitations at lower temperatures. Also
at lower temperature the rate-determining step for oxygen permeation was found to be oxygen reduction with the oxygen permeation performance
of the module being significantly enhanced by deposition of a porous platinum catalyst film onto the air-side of the membranes. A stable but mass
transfer limited flux of 0.56 ␮mol cm−2 s−1 (0.73 ml STP cm−2 min−1 ) was achieved after a period of 4 days of operation at 1000 ◦ C and continued
at this rate for a further 4 days. A non-mass transfer limited flux of ca 0.14 ␮mol cm−2 s−1 was obtained at 800 ◦ C. The membrane module was
operated for 500 h before the onset of significant leakage. Post operation qualitative analysis indicated localised changes in the stoichiometry of
the membranes with no discernable trend, quantitative analysis on the other hand revealed that the perovskite had retained its starting composition.
Post-operation analysis of the membranes revealed the presence of sulfur in the form of sulfates of strontium, cobalt and calcium and a change
of surface microstructure for both the air- and lumen-side membrane surfaces. Possible sources of this sulfur contamination are: the glass-ceramic
sealing material employed, the helium sweep gas and atmospheric sulfur dioxide. This contamination may contribute to the decrease in the long-
term oxygen permeation rates. The metal cation stoichiometry of the perovskite showed changes in localised areas of the membranes following
oxygen permeation studies.
© 2006 Elsevier B.V. All rights reserved.

Keywords: Perovskite; La0.6 Sr0.4 Co0.2 Fe0.8 O3 − δ ; Hollow fibre; Porous platinum catalyst film; Oxygen permeation

1. Introduction appropriate gas atmosphere compositions. Thus the material


is imparted with mixed ionic-electronic conducting (MIEC)
The rich magnetic, optical, redox and catalytic properties of properties.
metal oxides can be utilised for many applications [1]. Amongst When formed into dense membranes and subjected to high
the most studied family of metal oxides is the highly versa- temperatures and oxygen chemical potential differences, these
tile cubic perovskite phase [2–4]. These ABO3 solid oxides membranes can transport pure oxygen through the combination
are formed from combining lanthanide or group II element of mobile oxygen vacancies and electronic defects while simul-
cations (A-site cation) and typically, thought not exclusively, taneously excluding the transport of other gas-phase species.
first row transition metal cations (B-site cation) into the cubic Interest has grown in applying MIEC membranes to industrial
close packed structure. They possess rich defect chemistry processes such as air separation, oxidative coupling of methane
created by doping of suitable cations into the structure and evi- and synthesis gas production in catalytic membrane reactors
denced by the creation of oxygen vacancies within the oxygen (CMR) as they offer product separation and oxygen supply in
sublattice, VO•• , (represented in Kröger–Vink notation) and elec- one unit [5]. Commercial advantage can also be gained if freely
tronic n- and p-type conductivity at high temperature under available atmospheric oxygen is used. Their inherent electronic
conductivity removes the necessity of external circuitry to pump
the oxygen from one side to the other, simplifying the reactor
∗ Corresponding author. Tel.: +44 191 222 5279; fax: +44 191 222 5292. and also removing electrode-membrane contact resistances, an
E-mail address: I.Metcalfe@newcastle.ac.uk (I.S. Metcalfe). inherent problem with pure ionic conductors.

0376-7388/$ – see front matter © 2006 Elsevier B.V. All rights reserved.
doi:10.1016/j.memsci.2006.11.015
176 A. Thursfield, I.S. Metcalfe / Journal of Membrane Science 288 (2007) 175–187

The mechanism of oxygen transport through MIECs involves apparatus are described elsewhere [13,14]. Crystallinity and
oxygen disassociation and reduction on the membrane surface phase purity was ascertained by powder X-ray diffraction (XRD)
followed by incorporation into the perovskite lattice as oxygen using a PANalytical X’Pert Pro diffractometer fitted with a
anions, OxO (in Kröger–Vink notation), that can migrate through X’Celerator and employing Cu K␣ radiation, λ = 1.54180, or
the crystal lattice via oxygen vacancy defect sites. This pro- Cu K␣1, λ = 1.54059. A nominal step size of 0.033 degrees two-
cess is activated and can be hindered by slow surface kinetics theta with a step time of 100 s in continuous mode was routinely
at the membrane surface and long solid-state diffusional path used. Diffractograms were recorded on ground membrane sam-
length i.e., large membrane thicknesses. The impact of these ples and whole hollow fibre samples. A Röntec Quantax 1.2
two factors can be reduced by employing membranes of high FEI 30XL ESEM FEG system was used to perform scanning
surface area and small wall thickness. This can be achieved with electron microscopy (SEM) for microstructure characterisation
membranes in the form of hollow fibres. The hollow fibres pro- and for standard-less qualitative elemental analysis by energy
vide a high membrane surface area per unit volume of reactor dispersive X-ray analysis (EDS). Elemental mapping was per-
compared to the conventional disc and tubular forms typically formed after EDS to ascertain possible segregation of elements.
used. The hollow fibres have diameters typically ca 1–2 mm Quantitative analysis of the bulk composition of the used hol-
with wall thicknesses in the range 0.2–0.3 mm; disk and tube low fibre membranes was performed by Inductively Coupled
membranes typically have thicknesses of ca 1–2 mm. Interest in Plasma Optical Emission Spectroscopy (ICP-OES) using a Uni-
hollow fibres is growing, and a number of groups have begun cam 701 ICP-OES. Calibration for the elements of interest over
work in fabricating and characterising the structure and oxygen the range 0–100 ppm was done using certified single element
permeation performance of a number of perovskite based hol- standards. The sample was introduced at a rate of 1 ml min−1
low fibre membranes [6–17]. One of the most studied perovskite and the plasma was operated at a power of 1 kW with a coolant
membrane materials is La0.6 Sr0.4 Co0.2 Fe0.8 O33 − δ (abbreviated flow of 13 L min−1 and an auxiliary flow of 0.5 L min−1 .
to LSCF6428) because of its stability. Stability of the crystal
structure is crucial if commercial exploitation is to be realised 2.2. Catalytic surface modification
as degradation over time caused by kinetic demixing of the con-
stituent cations under a thermodynamic gradient may lead to A module was made comprising of four hollow fibres whose
membrane failure [18–20]. Catalytic modification of the mem- outer air-side surfaces were coated with a layer of platinum. A
brane surface can increase the rate of surface processes and platinum resinate (M603B supplied by Metalor, UK) containing
therefore the oxygen permeation performance when such pro- 14 wt% platinum was crudely applied onto the outer surface of
cesses are limiting. This approach has been tried, and proved the central 5 cm of each hollow fibre using a small fine brush. The
successful, using photolithography to deposit regularly spaced membranes were then fired using a programmed temperature
platinum disks onto a disk membrane of SrCo0.5 FeOx MIEC ramp of 10 ◦ C min−1 to 400 ◦ C, held for 1 h, then 10 ◦ C min−1 to
[21]. The oxygen permeation achieved was up to double that of 900 ◦ C, held for 1 h, and then 10 ◦ C min−1 to 25 ◦ C to remove the
an unmodified test sample of the same material in the tempera- organic resin and sinter the platinum metal onto the membrane
ture range 600–800 ◦ C. surface. The average surface loading of the catalytically modi-
In our previous work a hollow fibre membrane reactor of the fied hollow fibres was ca 3 mg cm−2 . Hollow fibre membranes
shell and tube type (with the tube replaced with a bundle of coated with platinum will be referred to hereafter as Pt-HF and
hollow fibres) was tested for oxygen permeation and methane uncoated as HF. A diagram of the hollow fibre reactor module
oxidation using catalytically unmodified membranes [22]. The is given in Fig. 1 with an expanded schematic of a single hollow
reactor was operated under conditions under which there was fibre indicating the central 5 cm exposed to the atmosphere.
an axial oxygen chemical potential gradient on both sides of the
membrane giving rise to a gradient in oxygen permeation rate. 2.3. Oxygen permeation experiments
In contrast to this, a gradientless reactor would allow oxygen
permeation rates to be accurately determined as a function of The membrane performance apparatus employed consisted
operating conditions. of gas supply and gas flow control, the hollow fibre reactor
In this contribution we report on the performance of a catalyt- module with furnace and online gas chromatography for anal-
ically unmodified and catalytically modified MIEC LSCF6428 ysis of the gas stream. All experiments were performed at a
gradient-less hollow fibre reactor module with respect to oxygen total pressure of one atmosphere on both sides of the mem-
permeation over the temperature range of 650–1000 ◦ C and also brane. The gas supply to the lumen-side of the reactor module
present information on post-operation characterisation. was controlled by an Aalborg mass flow controller calibrated
for 100% helium and ranged from 0 to 200 ml min−1 . All gas
2. Experimental flows are quoted at standard temperature and pressure (STP).
The upstream and downstream gas flow rates through the lumen
2.1. Characterisation were independently monitored using a digital flow meter (Var-
ian). The apparatus has been described elsewhere [22] and will
Commercial LSCF6428 (Praxair) was used to produce the not be repeated here, the only difference being the reactor mod-
dense hollow fibre membranes by the phase inversion tech- ules used in this work have no shell. A heating or cooling rate of
nique. This method and the membrane gas-tightness testing 1 ◦ C min−1 was used when required throughout this investiga-
A. Thursfield, I.S. Metcalfe / Journal of Membrane Science 288 (2007) 175–187 177

Fig. 1. Schematic of the shell-less hollow fibre membrane and magnified diagram of the platinum coated hollow fibre membrane area.

tion for the membrane modules. The temperature profile of this sumption on the air-side) and is adjusted so as to not include
furnace under operating conditions has been reported previously any contribution from leakage. The oxygen flux, jO2 , was deter-
[22]. In order to report fluxes and avoid the complication of oxy- mined by the percentage molar content of oxygen appearing in
gen flux as a function of position along the membrane, a coating the helium sweep gas, [O2 ], measured by gas chromatography
of glass ceramic sealant; 70% inorganic filler, composed mostly and using Eq. (2):
of barium sulfate, and also kaolin and silica flour, and the remain-
1 1 1
ing 30% is a binder, composed mostly of sodium and potassium jO2 = [O2 ]F (2)
silicates was applied to the outside of the hollow fibres. This Vm 60 SA
application was designed to pacify the oxygen permeation con- where F is the flow rate of the helium sweep gas in ml (STP)
tribution from the membrane outside of the central linear heated min−1 , Vm is the molar volume of the sweep gas (1 mol is
zone of 5 cm. The superficial active membrane surface area SA equivalent to 22400 ml at STP), the 1/60 factor converts the
thus provided by the module can be approximated by rate from minutes to seconds and the final term SA is 7.6 cm2
to give the flux (area specific, based on the simple projected
2π(ro − ri )
SA = nl (1) area of the active section of the hollow fibre membrane).
ln(ro /ri ) Oxygen permeation data were recorded 15 min after chang-
where ro and ri are the outer and inner radius of a typical ing the gas flow conditions and 30 min after each temperature
hollow fibre, n is the number of hollow fibres and l is the change.
active working length. The radii ro and ri were typically 0.07
and 0.05 cm, respectively, although this is an approximation 2.4. Membrane history
because of irregular wall thicknesses. Assuming that only the
central linear heating zone of the furnace is used (l = 5 cm) gives It can be important to know the history of membranes during a
an active membrane area of ca 7.6 cm2 provided by the four series of experiments as past treatment can influence behaviour.
hollow fibres. This central membrane area was then coated with The treatment history of the LSCF6428 membranes in the HF
a porous film of platinum for experiments with the catalytically and Pt-HF modules is as described in the sequential series of
modified membrane. experiments shown in Figs. 4–6. The information is summarised
One HF and one Pt-HF module were used for all of the exper- in Table 1. Treatment 1 represents the beginning of the exper-
iments described in this work. Throughout this work the side of iments with the modules being heated to the first operating
the membrane which is exposed to the constant oxygen partial temperature under air and treatment 50 indicates the cessation
pressure of the atmosphere is referred to as the air-side; the par- of the study on the Pt-HF as the module is cooled down to room
tial pressure of oxygen on this side of the membrane being pO2  . temperature under air. Also included are the heating and cooling
The other side of the membrane, the lumen-side, is referred to conditions between experiments and the duration of these steps.
as the sweep-side. About 99.999% helium (BOC, UK) (possi- The total operation time of the HF module was ca 43 h and for
ble contaminants are N2 at 5 ppm, O2 at 2 ppm, H2 at 1 ppm, the Pt-HF module ca 500 h.
CO2 at 0.5 ppm, H2 O at 1 ppm and C1–C5 hydrocarbons at a
total of 0.5 ppm) was used as the inlet sweep gas and therefore 3. Results and discussion
the inlet oxygen partial pressure at the lumen-side (denoted by
pO2  in ) was zero. The outlet oxygen partial pressure from the 3.1. Characterisation
lumen-side is denoted by pO2  out .
Permeation is determined by measuring oxygen evolution Prior to use each LSCF6428 hollow fibre was tested for gas-
through the hollow fibres on the lumen-side (as opposed to con- tightness and samples of the hollow fibres were ground for
178 A. Thursfield, I.S. Metcalfe / Journal of Membrane Science 288 (2007) 175–187

Table 1
Membrane treatment summary collated from Figs. 4–6
Treatment Relevant figure Experimental conditions

Heating/hold (◦ C) Cooling/hold (◦ C) Helium sweep rate(s) (ml min−1 )c Duration/hoursd

1 4 and 5a 25–650 0e 10.9


2 4 and 5 650 10–187 3.2
3 4 and 5 650–700 10 1.3
4 4 and 5 700 10–180 3.2
5 4 and 5 700–750 10 1.3
6 4 and 5 750 10–173 3.2
7 4 and 5 750–800 10 1.3
8 4 and 5 800 10–170 2.8
9 4 and 5 800–850 10 1.3
10 4 and 5 850 9–123 2.4
11 4 and 5 850–900 9 1.3
12 4 and 5 900 10–137 2.4
13 4 and 5 900–950 10 1.3
14 4 and 5 950 9–134 2.4
15 4 and 5 950–1000 9 1.3
16 4 and 5 1000 9–182 3.2
17 5b 1000–950 9 1.3
18 5 950 13–135 2.4
19 5 950–900 13 1.3
20 5 900 10–138 2.4
21 5 900–850 10 1.3
22 5 850 9–125 2.4
23 5 850–800 9 1.3
24 5 800 11–170 2.8
25 5 800–750 11 1.3
26 5 750 11–173 3.2
27 5 750–700 11 1.3
28 5 700 10–172 3.2
29 5 700–650 10 1.3
30 5 650 8–171 3.2
31 5 650–700 8 1.3
32 5 700 11–172 3.2
33 5 700–750 11 1.3
34 5 750 11–168 3.2
35 5 750–800 11 1.3
36 5 800 11–164 2.8
37 5 800–850 11 1.3
38 5 850 11–125 2.4
39 5 850–900 11 1.3
40 5 900 10–136 2.4
41 5 900–950 10 1.3
42 5 950 9–137 2.4
43 5 950–1000 9 1.3
44 5 1000 10–161 2.4
45 6b 1000 10 24
46 6 1000–750 10 4.6
47 6 750 100 192
48 6 750–1000 10 4.6
49 6 1000 100 192
50 1000–25 0e 16.3
a For Pt-HF and HF modules.
b Pt-HF module only.
c Flow rate(s) during experiments and temperature changes.
d Includes wait times for temperature stabilisation, sweep gas flow stabilisation and analysis time.
e In air.

powder XRD, which revealed that the membranes employed in are provided in Fig. 2. EDS analysis of these surfaces did not
this work had retained the original perovskite structure (powder reveal the presence of foreign elements and elemental mapping
pattern not shown). Images of the inner and outer surfaces and (not shown) did not indicate segregation of any of the constituent
cross-sectional microstructure of the as-prepared hollow fibres perovskite metals.
A. Thursfield, I.S. Metcalfe / Journal of Membrane Science 288 (2007) 175–187 179

Fig. 2. Representative SEM images of (a) the outer surface of the hollow fibre
membrane, (b) the lumen-side surface and (c) fracture surface.

The grain size is no larger than 5 ␮m, the surface (Fig. 2a)
is clean and shows almost no pores or cavities. The lumen-side
(Fig. 2b) reveals the presence of cavities and an uneven surface
due to nodules of grains. A fracture surface image (Fig. 2c)
indicated a degree of pitting but no pores. We conclude that the
membranes were adequate for use in this investigation.
In Fig. 3 typical micrograph images of the outer surface of a
hollow fibre coated with platinum following sintering are shown.
The crudely applied coating is not continuous as there are areas
of bare membrane where the LSCF6428 crystal grains can be
seen (Fig. 3a), the coating itself has a dispersion of island parti- Fig. 3. Representative SEM images of the outer surface of a hollow fibre mem-
brane with a discontinuous porous coating of platinum catalyst showing (a) zones
cle sizes (Fig. 3b). The platinum islands have a porous surface
of bare membrane and zones of platinum coverage, (b) islands of platinum with
structure, some of which exhibit pits revealing the membrane a range of sizes, (c) fine porosity of a typical platinum island with cavity and (d)
surface (Fig. 3c). The film can be seen in profile (Fig. 3d) and the platinum layer in profile sintered onto the outer membrane wall.
has a fairly uniform thickness of ca 0.2 ␮m.
180 A. Thursfield, I.S. Metcalfe / Journal of Membrane Science 288 (2007) 175–187

3.2. Oxygen permeation studies are unimportant, the overall mass transfer coefficient for oxygen
should be independent of the lumen-side flow rate. Indeed both
To ensure a meaningful oxygen flux is determined we must these conditions of gradientless operation and absence of mass
ensure that there are no significant axial oxygen partial pressure transfer resistances are satisfied when the flux is independent of
gradients on the lumen-side. This can be confirmed by mon- the lumen-side flow rate.
itoring the oxygen partial pressure difference between outlet In Fig. 4 the oxygen permeation fluxes of the Pt-HF and HF
and inlet on the lumen-side and if this difference is typically modules are compared under similar conditions. The hollow
greater than 10% of the partial pressure driving force at the fibre membranes in both modules were subject to treatments
inlet (i.e. 0.208 atm) then the lumen-side flow rate should be 1–16 inclusive as indicated in Table 1. At lower temperatures
increased. Here we choose a 10% difference in the driving force there is a large range of sweep gas flow rates in which the flux
as being significant as we do not at this stage know the exact is independent of sweep gas flow rate. This indicates that the
form of the dependence of flux on oxygen partial pressure but membrane is operating under conditions where mass transfer is
this figure would be reasonable in most cases with the excep- unimportant and where the reactor is effectively gradientless.
tion of highly non-linear behaviour. However, the ultimate test At higher temperatures there is no region observed where flux
that the difference in driving force is insignificant is that the is independent of the sweep gas flow rate. Furthermore, at lower
flux no longer depends on sweep gas flow rate as this flow rate temperatures the benefit of the catalyst is apparent, as up to
is increased. Furthermore, if external mass transfer resistances ca four times the oxygen permeation for a given set of condi-

Fig. 4. Comparison of the oxygen permeation performance of Pt-HF module represented by the () symbols with an HF module represented by the (夽) symbols
under the same conditions of temperature and helium sweep rate.
A. Thursfield, I.S. Metcalfe / Journal of Membrane Science 288 (2007) 175–187 181

tions is obtained. This indicates that the reduction of oxygen on affect is less pronounced in the 850–1000 ◦ C range compared
the airside must be the rate-determining step in the absence of to the 650–800 ◦ C range. The second heating cycle shows that
a catalyst and that mass transfer cannot be controlling on the there is little difference to the oxygen fluxes obtained in the
air-side when no catalyst is present. The highest oxygen flux preceding cooling cycle, although they are a little lower until
obtained was 0.75 ␮mol cm−2 s−1 , equivalent to an electrical 850 ◦ C is reached. On the first heating cycle from 650 to 1000 ◦ C
current density of 300 mA cm−2 . the oxygen vacancy concentration is being established but has
Following the first heating cycle presented in Fig. 4 not reached its steady state under these conditions. Upon cool-
(650–1000 ◦ C in 50 ◦ C steps, treatments 1–16 inclusive) a ing back to 650 ◦ C we observe higher oxygen fluxes than those
cooling cycle (950–650 ◦ C in 50 ◦ C steps, treatments 17–30 obtained during the first heating cycle due to the established
inclusive) and a second heating cycle (700–1000 ◦ C in 50 ◦ C higher vacancy concentration, this new concentration is closer
steps, treatments 31–44 inclusive) were carried out to examine to the steady state value for these operating conditions and upon
the effect of rapid heating and cooling on the oxygen perme- heating for the final time the increase in oxygen permeation is
ation behaviour. Each cycle took ca 24 h to complete. The data therefore modest. The situation may be complicated by pos-
are presented in Fig. 5. The first heating cycle exhibits lower sible structural changes of the perovskite to phases such as
fluxes to some degree at all temperatures except 1000 ◦ C. On brownmillerite at low temperatures. This phase contains ordered
cooling from 1000 to 650 ◦ C the oxygen flux is higher at all oxygen vacancies that present a barrier to solid state oxygen
temperatures compared to the first heating cycle, although the diffusion.

Fig. 5. Oxygen permeation performance of a shell-less Pt-HF module over the temperature range 650–1000 ◦ C; () symbols represent the first heating cycle
incorporated here from Fig. 4, (䊋) symbols represent the cooling cycle and (䊉) symbols represent the second heating cycle.
182 A. Thursfield, I.S. Metcalfe / Journal of Membrane Science 288 (2007) 175–187

sulfate and cobalt sulfate [24,25]. This possibility is discussed


further in the post-operation studies section. Another exam-
ple of contamination affecting oxygen permeation has recently
been provided by Viitanen et al. [27] they observed a decrease
in the oxygen permeation rate of a disc LSCF6428 membrane
over time in a dual chamber cell. They found evidence for the
deposition of a contaminating silicon oxide layer formed under
operating conditions from siloxane-containing grease in the gas
valves apparatus. We cannot eliminate the possibility that a sim-
ilar contamination process has occurred in this study because of
the presence of significant quantities of glass-ceramic cement
in direct contact with the membranes which when subjected to
high temperatures may take part in solid-state reactions. This
possibility is discussed later.
During these long term experiments the atmospheric oxy-
Fig. 6. Temporal oxygen permeation of the Pt-HF module at 750 and 1000 ◦ C.
gen leak into the helium sweep, possibly through membrane
The (䊉) symbols represent the oxygen permeation at a constant helium sweep degradation and/or aging of the glass-ceramic sealant, gradu-
of 100 ml min−1 at 750 ◦ C. In the top graph section the () symbols represent ally increased at 1000 ◦ C from an initial value of 0.01 ␮mol s−1
the oxygen permeation at a constant helium sweep of 100 ml min−1 at 1000 ◦ C. (ca 0.02 ml min−1 ) to 0.06 ␮mol s−1 (ca 0.08 ml min−1 ) in the
100 ml min−1 of helium sweep gas, the experiment was termi-
3.3. Long-term oxygen permeation studies on the Pt-HF nated at this point as it was deemed that an oxygen leak rate of
module around 10% of the solid state oxygen permeate was too high.

The oxygen permeation trend over longer periods of time than 3.4. Comparison with other geometries and materials
those employed in the preceding data was investigated firstly at
750 ◦ C and then at 1000 ◦ C, the data are presented in Fig. 6. At In order to put the performance of the LSCF6428 hollow fibre
1000 ◦ C the module is operating under mass transfer limitations. membranes into context, we now compare the performance of
Prior to the investigation conducted at 750 ◦ C, the module was the HF and Pt-HF modules used in this work with that of previous
held for 24 h at 1000 ◦ C (treatment 45) following on from the work using LSCF6428 in both disk and hollow fibre form and
last heating cycle of the experiment described in Fig. 5. The long where other perovskite materials have been used. The data are
term study at 1000 ◦ C followed on from the 8 day period where summarised in Table 2.
the module had been held for 8 days at 750 ◦ C. Two studies have used LSCF6428 membranes with similar
At 750 ◦ C the oxygen flux is initially ca 0.06 ␮mol thicknesses of 1.5 and 1.53 mm, respectively, [28,29]. Oxygen
cm−2 s−1 at a helium sweep rate of 100 ml min−1 . This value permeation rates with air on one side and an inert sweep on the
is close to the oxygen permeation rate obtained during the other at 900 ◦ C were reported to be 0.1 and 0.08 ␮mol cm−2 s−1 ,
first heating cycle described above. Over time however the respectively. Under the same conditions, the hollow fibres used
flux decreases to ca 0.02 ␮mol cm−2 s−1 . A similar trend was in this work show a flux of 0.2 ␮mol cm−2 s−1 . The thickness
reported by Kruidhof et al. [23], who used a La0.6 Sr0.4 CoO3 − δ of the hollow fibres used here is 0.25 mm and, as such, if solid
membrane. They observed a large decrease in the oxygen per- state diffusion were rate determining we would expect to see a
meation at 750 ◦ C over ca 400 h. This was explained in terms flux some six times greater than the fluxes for the thicker mem-
of changes in the oxygen stoichiometry and ordering of oxy- branes. The fact that this is not the case may suggest (one should
gen vacancies. At 1000 ◦ C the decrease is much less dramatic, be careful about drawing any conclusions from comparisons of
the permeation rate falling from ca 0.60 ␮mol cm−2 s−1 to ca fluxes from different studies) some element of surface rate con-
0.56 ␮mol cm−2 s−1 over the 8 day period. As well as oxygen trol. We note that there are differences between studies in which
stoichiometry changes within the membranes, another factor is hollow fibre LSCF6428 membranes have been used and that a
the possible removal, deactivation or detachment of the plat- higher oxygen flux has been obtained with unmodified hollow
inum catalyst layer over time. The removal or deactivation of fibre membranes at a lower temperature (900 ◦ C) [14] than the
this layer would be expected to have a large impact on the oxy- maximum used (1000 ◦ C) in this contribution. The differences
gen permeation at 750 ◦ C where surface processes dominate. In between studies may lie in the sample treatment history and the
contrast, at 1000 ◦ C, surface processes are less important and use of a shell. A shell can protect the outer surface of the mem-
the effect would be more modest. The decrease in the oxygen brane from contaminants that may be present in the atmosphere
flux with time has also been reported with tubular membranes of or that may evolve from the furnace tube and deposit onto the
LSCF6428 operated at 850 ◦ C [24,25] and more recently with membrane and degrade performance over time.
hollow fibre membranes of BaCox Fey Zrz O33 − δ also operated at The LSCF6428 membrane material is only one of an ever
850 ◦ C [26]. The reason for this decrease was reported to be con- increasing number of perovskites being investigated for oxygen
tamination of the membrane with sulfur from the synthetic air permeation and methane oxidation reactions. In recent years
gas supply, in the form of sulfur dioxide forming both strontium Ba0.5 Sr0.5 Co0.8 Fe0.2 O33 − δ (BSCF5582) [8] and its zirconia
A. Thursfield, I.S. Metcalfe / Journal of Membrane Science 288 (2007) 175–187 183

Table 2
Comparison of oxygen permeation performance of hollow fibre membranes of LSCF6428 with other MIEC perovskite materials
Hollow fibre membrane material Thickness (mm) Temperature (◦ C) Flux jO2 a Atmospheres used Ref.

ml cm−2 min−1 ␮mol cm−2 s−1 Low pO2  /high pO2 

La0.6 Sr0.4 Co0.2 Fe0.8 O3 − δ 0.2 700–900 0.1–0.8 0.07–0.55 Ar/air [13]
La0.6 Sr0.4 Co0.2 Fe0.8 O3 − δ 0.3 800–900 0.1–1.2 0.07–0.9 Ar/air [14]
La0.6 Sr0.4 Co0.2 Fe0.8 O3 − δ 0.2 543–958 0.09–0.42 0.07–0.3 He/air [22]
La0.6 Sr0.4 Co0.2 Fe0.8 O3 − δ 0.2 858 0.26–0.8 0.2–0.6 0.022 atm CH4 /He/air [22]
La0.6 Sr0.4 Co0.2 Fe0.8 O3 − δ (HF module) 0.2 650–1000 0.007–0.65b 0.005–0.5b He/laboratory air This work
La0.6 Sr0.4 Co0.2 Fe0.8 O3 − δ (Pt-HF module) 0.2 650–1000 0.02–1.0b 0.015–0.75b He/laboratory air This work
La0.6 Sr0.4 Co0.2 Fe0.8 O3 − δ (Pt-HF module) 0.2 1000 0.73b,c 0.56b,c He/laboratory air This work
La0.6 Sr0.4 Co0.2 Fe0.8 O3 − δ (Pt-HF module) 0.2 750 0.03d 0.02d He/laboratory air This work
BaZrx Coy Fez O3 − δ e 0.18 800–900 5–7.6 2.98–5.65 0.04–0.06 O2 atm/He/air 26
Ba0.5 Sr0.5 Co0.8 Fe0.2 O3 − δ 0.2 700–950 0.69–5 0.51–3.72 He/air (no shell) 31
a STP assumed if not stated.
b Fluxes include mass and non-mass transfer limited values.
c Steady value after 4 days of operation.
d Value after 8 days of operation.
e Stoichiometry not given.

containing analogue BaZrx Coy Fez O33 − δ [26] (the stoichiom- peaks can be observed in the 2θ range 23–52◦ . These low inten-
etry of which has not been provided for proprietary reasons) sity peaks become noticeably stronger relative to the perovskite
have been developed and reported to possess impressive long phase when analysis of the intact membrane air-side surface is
term stability during oxygen permeation and hydrocarbon oxida- performed (Fig. 7c). We assign these peaks to strontium sulfate
tion studies. These materials have provided the highest reported as an excellent match with PDF 05–0593 was made. Additional
fluxes in the open literature to date, ca 5 and 7.6 times higher information from EDS described in the following discussion
than the maximum flux obtained from the Pt-HF membranes helped to confirm the presence of this phase. Platinum could
used here. not be detected in the Pt-HF membrane samples by XRD as its
reflections are coincident with that of the perovskite phase. The
3.5. Post operation characterisation intact membrane surface on the lumen-side on the other hand
shows only the perovskite phase (Fig. 7d).
After operation, each module was cooled down at 1 ◦ C min−1 The external membrane surface (air exposed side), membrane
to room temperature, removed from the furnace and visually wall cross section (the bulk) and the lumen-side membrane sur-
inspected. The HF module had a number of dark blue patches at face (helium sweep gas exposed side) microstructures of the
the hollow fibre-ceramic cement boundary. The Pt-HF module membranes were investigated by SEM and qualitative elemental
was inspected and it was observed that: (a) the metallic lustre analysis performed by EDS with elemental mapping.
of the platinum coating on the central 5 cm zone of the mem-
branes was no longer present, (b) approximately 2–3 cm either 3.5.1. HF module
side of this zone the pacifying cement coating was blackened, The air-side surface of the HF module was found to be pit-
and (c) there were patches of dark blue colouration with a shiny ted and covered in plates, an image of a representative example
smooth appearance in areas where the cement was blackened is provided in Fig. 8a. The pits are ca 50 ␮m in diameter and
and in areas were the cement retained its original colour. We are decorated with plates. EDS with elemental mapping (not
conclude that over the course of the oxygen permeation experi- shown) revealed the presence of lanthanum, strontium, cobalt,
ments the ceramic-glass water based cement and the hollow fibre iron, calcium and sulfur on the air-side membrane surface, rep-
had reacted and that cobalt had leached out of the LSCF6428 and resentative data are provided in Table 3. Calcium was found
deposited onto the cement surface. The affect was more severe
for the Pt-HF module possibly as it had been used for a longer Table 3
period of time at high temperature. Samples of the central 5 cm Representative post operation EDS data of the surfaces of the LSCF6428 mem-
hollow fibre membranes from both modules were removed for branes from the HF module
SEM, EDS, ICP and powder XRD analysis. Location Approximate atom (%)
Fig. 7a and b show the XRD powder patterns for the HF and
Pt-HF samples, respectively. These diffraction patterns are the La Sr Co Fe Ca S
bulk response and not surface specific, no preferred orientation Shell-side pit interior 0.8 16.9 8.9 1.4 26.6 45.3
was assumed for the crystallites. The powder diffraction patterns Shell-side pit edge 16.8 11.6 10.6 29.8 16.2 15.1
are very similar. The main perovskite structure has remained Shell-side away from pit 29.7 13.9 10.3 39.1 0 7.0
Bulk 33.3 22.5 8.9 35.2 0 ∼0.1
intact but with splitting of the main reflections indicating a Lumen-side 34.5 4.9 12.9 47.5 0 0.2
lowering of symmetry. In addition, a number of less intense
184 A. Thursfield, I.S. Metcalfe / Journal of Membrane Science 288 (2007) 175–187

Fig. 8. Representative post operation SEM images of the HF module: (a) the
outer surface of the hollow fibre membrane showing a typical pit, (b) the outer
surface of the hollow fibre membrane away from pitted areas, and (c) the lumen-
side.

to be concentrated only at the pits along with particularly high


concentrations of sulfur. The calcium may have its origins in the
municipal water used in the hollow fibre forming process and
also from the furnace alumina tube insert. The chemical analysis
data sheet of the furnace tube indicated the presence of 0.14%
calcium oxide and 2.88% potassium oxide, however, potassium
was not observed in the EDS spectra of the membrane. To a
Fig. 7. Post operation powder XRD patterns of the (a) HF and (b) Pt-HF mem-
branes. Inset is the expanded region indicating the presence of strontium sulfate.
lesser degree, cobalt and strontium were also detected at these
Also shown is a representative (c) XRD pattern of the intact air-side membrane pits, probably also in the form of sulfates while lanthanum and
surface of the Pt-HF module strongly indicating the presence of strontium sulfate iron were almost completely absent. The localisation of cobalt
and (d) XRD pattern of the intact lumen-side membrane surface of the Pt-HF and calcium sulfate at these pits meant that these sulfates were
module revealing the absence of sulfate containing phases. not revealed in the powder XRD diffractogram. Away from the
pits (Fig. 8b) the membrane surface has broken up into small
A. Thursfield, I.S. Metcalfe / Journal of Membrane Science 288 (2007) 175–187 185

crystallites to give a rough surface, EDS and elemental map-


ping indicated an even covering of sulfur and the constituent
LSCF6428 perovskite metals in a range of stoichiometries, but
no calcium. The air-side sulfur away from the pits is probably
in the form of strontium sulfate as indicated by XRD.
The lumen-side surface was found to be decorated with crys-
tals and small, shallow cavities (Fig. 8c). The observed ridges
are a product of the hollow fibre forming process and not as
a result of microstructural change due to the imposed oxygen
permeation or other experimental conditions.
EDS revealed the presence of sulfur on the lumen-side and
surprisingly, within the membrane bulk at low levels. The form
which this bulk sulfur takes is not clear as the sulfide anion is
too large to take up positions at oxygen sites within the per-
ovskite structure. The presence of sulfur within the membrane
bulk has recently been reported in a similar study to this using
BaCox Fey Zrz O3 − δ hollow fibre membranes [26]. A tentative
explanation is that sulfates have migrated through fissures, too
small to be observed by SEM, at the membrane surface and have
entered and diffused through the bulk, though there is no direct
evidence for this. In addition we cannot rule out the possibility
of contamination during fracturing of the sample for analysis.

3.5.2. Pt-HF module


The air-side surface of the Pt-HF module was found to be
more complicated. The surface at the central 5 cm zone appeared
to be decorated with crystals of a range of sizes (Fig. 9a) but did
not show pits as was observed for the HF membranes, possi-
bly due to the platinum layer blocking their development. The
surface is markedly different to the preoperational air-side sur-
face (Fig. 3a–c) where clearly defined regions of platinum were
observed. Before operation there are Pt islands with clear surface
porosity. Post-operation, there is no clear porosity, possibly due
to sintering during operation. The removal of the metallic lustre
from the Pt-HF membranes did not result in a loss of the observed
enhancement of the oxygen permeation. EDS analysis (sum-
marised in Table 4) of the air-side membrane surface indicated
the presence of mostly sulfur (up to ca 60 atom %) and small
amounts of localised platinum (ca 3–7 atom %) along with the
constituent perovskite metals of the membrane in a wide range
of molar ratios. However, quantitative ICP of a bulk membrane
sample indicated that the nominal LSCF6428 stoichiometry was
maintained. Close to the pacifying cement-(Pt-HF) interface an
interesting structure can be observed resembling a continuum

Table 4
Representative post operation EDS data of the surfaces of the LSCF6428 mem-
branes from the Pt-HF module
Location Approximate atom (%)
La Sr Co Fe S Pt Al Si Ba

Shell-side (e.g. 1) 2.2 28.2 0.8 1.4 60.3 7.1 0 0 0


Shell-side (e.g. 2) 3.2 31.5 1.3 4.7 56.0 3.3 0 0 0
Shell-sidea 5.6 33.8 4.0 6.9 43.2 0 2.9 2.1 0.8 Fig. 9. Post operation representative SEM images of the Pt-HF module: (a) the
Bulk 22.1 25.6 12.9 33.0 0 0 6.4 0 0 outer surface of the hollow fibre membrane at the center, (b) the outer surface of
Lumen-side 27.3 18.9 8.5 35.7 0 0 9.6 0 0 the hollow fibre near the cement, (c) magnified image of (b) and (d) lumen-side
surface showing uneven surface with large raised protrusions and cavities.
a See Fig. 9b.
186 A. Thursfield, I.S. Metcalfe / Journal of Membrane Science 288 (2007) 175–187

of connected depressions (Fig. 9b). It appears on first inspection sulfate formation but we cannot separate out its contribution
that either a matrix has been deposited on the membrane surface, from that from the cement. The helium sweep gas supply has
or, that grain growth followed by preferential smooth erosion of also been cited in other work as a source of sulfur contamination
the grains to leave a prominent grain boundary has occurred. A in the form of sulfur dioxide [24,25] with different helium gas
higher magnification reveals that this surface structure contains cylinders possibly containing different levels of sulfur contam-
fine cracks (Fig. 9c). Such a structure was not observed with the ination. This may be the reason why sulfur was detected on the
HF module, possibly due to its shorter period of operation at lumen-side surface of the HF module but not on the lumen-side
high temperature. EDS analysis in this area again gave a wide of the Pt-HF module following the oxygen permeation studies.
range of stoichiometries of the perovskite constituent metals but Against this argument is the lack of sulfur contaminants in the
with consistently higher proportions of strontium and sulfur in supplier’s specification of purity. The formation of the strontium
an approximate 1:1 ratio indicating the presence of strontium sulfate phase on the membrane air-side surface over time may
sulfate. Also present at low concentrations were the component play a role in the observed decrease of the oxygen flux observed
elements of the heavy grade cement. at 750 and 1000 ◦ C (Fig. 6).
The lumen-side, at the central 5 cm zone and within the In addition, other phases such as cobalt sulfate, cobalt oxide,
areas where the membrane was covered by the cement, revealed strontium oxide and lanthanum oxide have been found, specif-
the presence of large protrusions, cavities and deposits of iso- ically on LSCF6428 membranes [24,25]. The authors also
lated crystal grains (Fig. 9d). The internal microstructure had presented EDS data that indicated cobalt and iron had segre-
deformed in comparison to the pre-operation state (Fig. 2) prob- gated to the air-side of the membrane [25] in accordance with
ably indicating pending failure. EDS indicated that lanthanum, the theory of kinetic demixing [18–20]. These additional phases,
strontium, cobalt and iron were in their nominal pre-operation and cobalt and iron enrichment at the air-side of the membrane,
stoichiometric ratios but also that aluminium was present at sim- could not be found in this post-operation study within the detec-
ilar atom % concentrations as cobalt. No sulfur was detected on tion limits of the instrument used, only strontium sulfate was
the lumen-side surface. found to be present with a high degree of certainty. The EDS
EDS analysis of the Pt-HF membrane bulk indicated a mix of elemental analysis did not reveal any particular trend in the
the perovskite metal stoichiometries with no discernable pattern perovskite cation stoichiometry as a function of location in the
and significant amounts of evenly distributed aluminium and the membrane bulk indicating that on the time scale of the exper-
absence of sulfur. The aluminium probably originates from the iment, detectable segregation of cobalt or iron at the air-side
kaolin component of the cement. At 1000 ◦ C over a period of 8 region of the membrane had not occurred. The localised differ-
days it is possible that the Al3+ cation could diffuse through the ences in the perovskite cation stoichiometry may indicate the
perovskite by solid-state reaction. EDS of the HF module did onset of demixing after ca 21 days (ca 500 h) of operation, but
not indicate the presence of aluminium within the instrument’s the module was not used for a long enough period at high tem-
detection limits, which may be attributed to its shorter time of perature to conclusively show evidence, for example, of cobalt
operation at 1000 ◦ C. We note also the absence of barium in both and iron segregation at the air-side of the membrane. A study by
sets of membrane samples within the detection limits of EDS. Lein et al. [30] has shown that after around 30 days of operation
The membrane cross-sectional microstructure of the HF and at 1150 ◦ C kinetic demixing of La–Sr–Co–Fe oxide membranes
Pt-HF membranes had not changed in comparison to the pre- can occur.
operation state and so micrographs are not shown.
4. Conclusions
3.5.3. Sulfur contamination and kinetic demixing
The presence of sulfur has four possible sources: (a) from Catalytically modified and unmodified gas-tight hollow fibre
trace amounts of polyethersulfone from the phase inversion membranes of LSCF6428 have been used for air separation in
method used to form the hollow fibres into a dope, (b) from the absence of axial oxygen partial pressure gradients. A stable
the cement, (c) from trace amounts of sulfur dioxide in the air mass transfer limited flux of 0.56 ␮mol cm−2 s−1 was obtained
(in urban areas at the 1 ppb level) and (d) from the helium sweep after 4 days of operation at 1000 ◦ C, the flux remained at this
gas supply. The first possible source seems unlikely as sinter- level for a further 4 days before the study was terminated. A
ing of the green was performed at 1200 ◦ C, sufficient to burn non-mass transfer limited flux of ca 0.14 ␮mol cm−2 s−1 was
off all of the organics used in the forming process. It may be obtained at 800 ◦ C. The deposition of platinum catalyst onto
possible however that during this burning-off period the sulfur the surface of LSCF6428 MIEC hollow fibre membranes can
reacts with strontium in the presence of air to form the stron- increase the rate of oxygen reduction at the air-side mem-
tium sulfate phase but XRD and EDS did not show the presence brane surface and provides an overall increase in the oxygen
of sulfur or sulfur containing phases on either the lumen- or permeation rate. This indicates that under these conditions oxy-
air-side prior to use. The cement contains significant quantities gen reduction on the air-side is rate-determining. The module
of sulfur and it is most likely that the observed sulfur is from comprising the catalytically modified hollow fibres membranes
this source. A number of previous post-operation oxygen per- maintained sealing integrity for ca 500 h of operation involving
meation studies have reported the presence of sulfur containing many changes of temperature and oxygen chemical potential dif-
phases on perovskite MIEC membranes with one source being ference across the membranes before the onset of a significant
atmospheric sulfur dioxide which would certainly contribute to leak.
A. Thursfield, I.S. Metcalfe / Journal of Membrane Science 288 (2007) 175–187 187

The formation of strontium sulfate occurred on the air-side [10] X. Tan, S. Liu, K. Li, Preparation and characterization of inorganic hollow
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GR/S12197. The authors wish to thank Dr. Kang Li and Dr. Tan 94.
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