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Renewable and Sustainable Energy Reviews 15 (2011) 1284–1293

Contents lists available at ScienceDirect

Renewable and Sustainable Energy Reviews


journal homepage: www.elsevier.com/locate/rser

Oxygen separation from air using ceramic-based membrane technology


for sustainable fuel production and power generation
S.S. Hashim, A.R. Mohamed, S. Bhatia ∗
School of Chemical Engineering, Universiti Sains Malaysia, Engineering Campus, 14300 Nibong Tebal, Penang, Malaysia

a r t i c l e i n f o a b s t r a c t

Article history: There has been tremendous progress in membrane technology for gas separation, in particular oxygen
Received 28 May 2010 separation from air in the last 20 years providing an alternative route to the existing conventional separa-
Accepted 13 October 2010 tion processes such as cryogenic distillation and pressure swing adsorption. This paper covers the review
of membrane separation process and recent developments of ceramic membranes for oxygen separation
Keywords: from air. This membrane based oxygen supply from air offers significant advantages for integration in
Ceramic membranes
power generation cycles with carbon dioxide (CO2 ) capture, coal gasification systems and gas-to-liquid
Oxygen separation from air
(GTL) plants. The critical issues in the implementation of membrane technology for power generation
Power generation
CO2 capture
and fuel production are also presented and discussed.
Coal gasification © 2010 Elsevier Ltd. All rights reserved.
GTL

Contents

1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1285
1.1. The advances of air separation techniques for oxygen production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1285
1.2. Cryogenic air separation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1285
1.3. Swing adsorption-based systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1285
1.4. Mixed ionic–electronic conducting ceramic-based membranes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1286
1.5. Comparisons of process alternatives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1286
2. Membranes for sustainable fuel production and power generation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1286
2.1. Oxyfuel combustion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1286
2.2. Gasification systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1288
2.3. Coal gasification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1288
2.4. Gas-to-liquid (GTL) process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1289
3. Progress in high temperature membrane-based separation for oxygen production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1289
3.1. Advanced zero emissions power plant (AZEP) project . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1289
3.2. Zero emission ion transport membrane oxygen power (ZEITMOP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1290
3.3. OXYCOAL-AC project at RWTH Aachen University . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1290
4. Critical issues in the implementation of membrane-based separation technology for oxygen production in the power generation and
fuel production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1291
5. The way forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1291
6. Concluding remarks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1292
Acknowledgements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1292
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1292

∗ Corresponding author. Tel.: +60 4 5996409; fax: +60 4 5941013.


E-mail address: chbhatia@eng.usm.my (S. Bhatia).

1364-0321/$ – see front matter © 2010 Elsevier Ltd. All rights reserved.
doi:10.1016/j.rser.2010.10.002
S.S. Hashim et al. / Renewable and Sustainable Energy Reviews 15 (2011) 1284–1293 1285

1. Introduction modern air compressors with high efficiency and advanced aero-
dynamic design will be available for the large single train oxygen
1.1. The advances of air separation techniques for oxygen plants of up to 10,000 tons/day capacity, which is required for
production power and hydrogen systems with CO2 capture. It has been noted
that there have been re-engineering efforts by some industrial gas
Oxygen constitutes 21 vol.% of the air. It is among the most producers to reduce the energy consumption and both capital and
widely used commodity chemicals in the world [1], with numer- operating costs. For instance, the use of packed towers instead of
ous applications in almost every industrial sector. The separation of the traditional trayed towers have been implemented, while others
oxygen from air is a big business, where nearly 100 million tons of are working on improving heat exchangers, high efficiency com-
oxygen are produced every year [2]. This oxygen market is believed pressors and control systems that provide real time optimization
to be expanding in the coming years because all large-scale clean [7]. Some of these companies are also investigating on employing
energy technologies will require oxygen as a feed [3]. More recently, higher operating pressures to reduce the overall distillation column
strong demand for tonnage quantities of oxygen is encouraged by diameter. Coupled with fully utilization of the cryogenic distil-
the steady growth in chemical process operations. For instance, lation process, current approaches towards reducing the energy
oxyfuel combustion process and oxygen-blown gasification to con- requirements of this conventional air separation technology for
vert coal and natural gas into an intermediate synthesis gas that can large quantities of oxygen production are well in progress.
be further processed to produce electricity, chemicals and trans-
portation fuels. There have been two fundamental approaches for 1.3. Swing adsorption-based systems
air separation, which are cryogenic and non-cryogenic distillation.
The cryogenic distillation is typically reserved for applications that The utilization of swing adsorption (SA) in the production of
require tonnage quantity of oxygen at ultra-low-temperature. The oxygen from air separation has been recognized and is mainly
latter involves the separation of air at ambient temperatures using dominated by large gas separation companies such as BOC, Prax-
either molecular sieve adsorbents via pressure swing adsorption air, Air Products & Chemicals, Air Liquide, and Linde. Swing
(PSA), or membrane separation process using the polymeric mem- adsorption technology is suitable for small to medium-scale
branes. Meanwhile, there is an air separation technique by chemical plant (20–100 tons/day); hence, it is not applicable to large-scale
processes that is based on the ability of certain materials, such as (100–300 tons/day and beyond) production of oxygen, which is
molten salt to absorb and desorb oxygen at particular pressure and typically carried out by cryogenic distillation processes. Swing
temperature conditions [4]. Air Products and Chemicals operated adsorption process seems to be the best alternative because of
a small-scale pilot plant using this technique; however, this tech- the matured technology, adsorbents availability as well as a low
nique was not cost effective because of the corrosion of salt/oxygen cost energy, and highly efficient gas separation system [8,9]. Vac-
two-phase areas of the plant [4]. Recently, a third category of air uum swing adsorption (VSA), pressure swing adsorption (PSA),
separation has emerged, which is based on specialized ceramic temperature swing adsorption (TSA) and hybrid vacuum-pressure
membranes that separate oxygen from air at elevated tempera- swing adsorption (VPSA) or temperature–pressure swing adsorp-
tures, in contrast to the super-cooled temperatures required by tion (TPSA) systems are the variation of this technology. Most of
conventional cryogenic distillation. Extensive demonstration-scale these systems are relied entirely on zeolites to trap nitrogen in
testing suggests that this approach will lead to the development of order to produce oxygen with purities from 90% to 95%. It is noted
compact systems that produce tonnage oxygen supply with signif- that the zeolites A and X are the most important component as
icant advantages, in terms of reductions in capital cost and energy an adsorbent in the oxygen-pressure swing adsorption (O2 -PSA)
requirements. Advances in these three main techniques are dis- process [10]. Hitherto, the investigation on the processes with dif-
cussed below. ferent adsorbents and operational conditions has been done by
few researchers. Recently, a new adsorbent, namely AgLiLsx was
1.2. Cryogenic air separation described in a patent by Air Products & Chemicals [11] for use in
a vacuum pressure swing adsorption for the production of high
Cryogenic air separation is the conventional technology for pro- purity oxygen from air separation. In addition, Mendes and co-
ducing large quantities of oxygen. This technology was pioneered workers [11] investigated on the use of silver exchanged zeolite
in the early 1900s and is still used today to produce high purity for oxygen separation from air while Zahra et al. [8] experimen-
oxygen [5]. While currently tonnage quantities of oxygen (oxygen tally and theoretically evaluated the four-bed PSA process using a
concentration ≥99%) are carried out by the cryogenic distillation commercial 13X zeolite.
process, this technology is noted to be complex, expensive and Ceramic authothermal recovery (CAR) technology is developed
energy intensive. By cryogenic distillation, the inlet air must be by BOC Group for air separation and partial oxidation of hydrocar-
filtered, compressed and chilled to about −185 ◦ C. Thereafter, bons [12]. This concept was based on the adsorption and storage
the liquefied stream is distilled in large distillation towers to of oxygen at high temperatures, typically 600–800 ◦ C. The process
separate air into its component phases (78 vol.% nitrogen, 21 vol.% employs fixed-bed vessel with multiple beds that are filled with
oxygen, 1 vol.% argon and other trace gases), according to their extruded pellets of ceramic perovskites, sandwiched between lay-
boiling points. The use of cryogenic distillation for oxygen supply ers of alumina beads. This process operates more or less similar to a
(oxygen concentration ≥95%) in the field of oxyfuel power plant PSA system, where multiple beds are cycled back and forth between
and coal gasification has meanwhile reduced the power generation adsorption and desorption modes enabling continuous production
efficiencies from current best practice of around 40–30% [3]; of an oxygen stream. The CAR process offers a significant advance-
therefore, it is vital to optimize the energy efficiencies of cryogenic ment in air separation technology because the oxygen production
air separation method for feasible energy delivery technologies. cost is estimated to be 20–30% lower than the cryogenic air sepa-
Multi-tower processes, lowering the process air pressure and ration technology [12]. However, it has been estimated that there
more efficient compression are few strategies implemented that will be an increase of the electricity cost of about 26% for a CAR
practically resulting to the 20% energy savings. This particular integrated coal-fired power plant [12]. The main hurdles towards
separation technology is almost reaching its maturity level. It the commercialization of CAR process are the cost of perovskite
relies on the improved turbine, compressor and heat exchanger and the impact of impurities on this particular material. As a final
efficiencies for better performances [6]. According to Allam [7], remark, a good performance of adsorption processes relies on the
1286 S.S. Hashim et al. / Renewable and Sustainable Energy Reviews 15 (2011) 1284–1293

800- 900oC problems. More recently, ceramic membranes are foreseen as the
7- 20 bar best candidate to replace cryogenic technology for high purity, ton-
Pressurized 1 Oxygen nage supply of oxygen from air separation at high temperatures.
air feed 2 depleted air Non-permeate Similar to the other non-cryogenic processes, this technology is
engaged with the production of pure byproducts and liquids for
MIEC ceramic O2- O2- Oxygen vacancies
membrane
Electron Electron
in lattice
storage and backup. Table 1 compares various oxygen produc-
tion technologies, where the status of the technologies is from
Oxygen rich 1 Sweep gas Permeate
stream 2 matured cryogenic through developing ceramic membranes. As
for the economy-feasibility technology comparison, less-efficient
Low pressure
but simple adsorption and polymeric membrane systems are pre-
Fig. 1. Schematic representation of the oxygen transport in dense MIEC ceramic ferred at lower production rates. The cryogenic process is excellent
membrane. in producing relatively pure nitrogen or argon streams. All tech-
nologies, except polymeric membrane systems are able to produce
pressure; however, increasing the pressure causes the increase in oxygen at maximum purity. Adsorption and polymeric membrane
cost. In brief, it is crucial to optimize this situation in order for systems require less time to restart the process and reach purity
adsorption-based oxygen separation from air technology enters the after a shutdown. Apart from the fact that integrating ceramic
non-traditional industrial gas markets. membranes can reduce oxygen energy costs by more than 35% as
in comparison to the conventional separation technology [14,15],
1.4. Mixed ionic–electronic conducting ceramic-based the potential of these membranes for oxygen separation from air
membranes at high temperatures in industrial scale is not fully developed. This
is due to the non-availability of general design methodologies and
Meanwhile, there is another promisingly potential technology comprehensive process know-how. Therefore, it is wise to develop
for oxygen separation from air, which is an alternative to the con- the modeling of membrane processes integrating with the process
ventional cryogenic air separation. This novel technique is based simulator to model membrane separation process, predictive mem-
on dense ceramic membranes, which carry out the separation of brane and module performance models. This paper will focus on the
oxygen from air at elevated temperatures, typically 800–900 ◦ C. In recent advances of ceramic membranes suitably for oxygen sepa-
the past decades, enormous efforts have been directed to ceramic ration from air and their integration in power generation cycles
membranes with mixed ionic–electronic conducting (MIEC) char- with carbon dioxide (CO2 ) capture, coal gasification systems and
acteristics due to their potential application of producing high gas-to-liquid (GTL) plants. The issues and problems regarding the
purity oxygen. Interestingly, these membranes require neither implementation of this new technology for power generation and
electrodes nor an external circuit to operate. As conceptualized energy conversion processes will be further discussed, as well as the
in Fig. 1, the electronic conductivity itself performs as an internal future directions of ceramic-based membrane for the production of
short circuit that involves oxygen partial pressure gradient. The O2 tonnage supply of oxygen from air separation.
permeates from the high oxygen partial pressure side to the low
oxygen partial pressure side, while the overall charge neutrality
is maintained by counterbalancing the flux of electrons [13]. Sev- 2. Membranes for sustainable fuel production and power
eral industrial gas companies are working on developing ceramic generation
membranes for oxygen separation from air at high temperatures.
Air Products and Chemicals has developed an ion transport mem- 2.1. Oxyfuel combustion
brane (ITM) system, which is based on patented, high temperature
ceramic membranes for the production of oxygen from air sep- Oxyfuel combustion, also called oxyfired, oxycombustion or
aration. Praxair is also working on oxygen-conducting ceramic oxycoal combustion technology uses oxygen instead of air for fuel
membrane systems that are specially designed to separate oxygen combustion, which produces flue gas that contains mostly of H2 O
from air at elevated temperature environment. and CO2 that are readily captured [16]. By oxyfuel combustion pro-
cess, coal is burned in a high-oxygen environment rather than in
1.5. Comparisons of process alternatives an air-based environment. The exhaust combustion flue gas stream
turns out to be more highly concentrated in CO2 by keeping out the
The ongoing improvements of the adsorption and polymeric nitrogen from the system. Pure CO2 is easily captured, compressed
membrane processes in both energy and cost efficient are expected and liquefied that can be sold or sequestered using particular meth-
through continuous research and development of adsorbents and ods as reported elsewhere [17,18]. CO2 concentrations above 90%
membrane materials. Both adsorption and polymeric membrane are obtainable. It is noticeable that the penalty for purification and
systems yield nitrogen containing a significant amount of oxygen compression of the CO2 by oxyfuel combustion can be reduced
as a byproduct; on the contrary, these processes are less compli- to around 110–170 kWh/tCO2 [19,20]. However, the production of
cated and more passive than the cryogenic process. Meanwhile, oxygen in oxyfuel power plants has been resulting to the rise of an
chemical processes show the potential for continuous operation extra energy demand.
and economies of scale through large production output from single It is worthwhile to be noted that there are two different tech-
trains; on the other hand, the material corrosion is one of the major niques for the production of oxygen in the oxyfuel power plants.

Table 1
The comparisons of process alternatives for oxygen production from air separation [4].

Process Status Economic range (sTPD) Byproduct capability Purity limit (vol.%) Start-up time

Cryogenic Mature >20 Excellent 99+ Hours


Adsorption Semi-mature <150 Poor 95 Minutes
Polymeric membrane Semi-mature <20 Poor ∼40 Minutes
Chemical Developing Undetermined Poor 99+ Hours
Ceramic membrane Developing Undetermined Poor 99+ Hours
S.S. Hashim et al. / Renewable and Sustainable Energy Reviews 15 (2011) 1284–1293 1287

Fig. 2. Schematic of an oxyfuel power plant incorporating MIEC membrane module [3].

Allam [7] has presented an overview on the development stage of lated flue gas over the membrane surface is employed; thus, the
oxygen production techniques in his paper, while Ekstrom et al. [21] oxygen can be assimilated directly. This so-called four-end con-
have successfully evaluated these techniques in terms of economic cept [25–27] is designated for IGCC processes; however, membrane
perspectives. Cryogenic air separation is a well-established method materials with high permeation rate like Ba0.5 Sr0.5 CO0.8 Fe0.2 O3−ı
for large-scale oxygen production, but the operation of the cryo- (BSCF) are not CO2 -resistant. As a result, the BSCF membranes can
genic separation unit consumes about 15% of the electrical output of only be applied when there is no direct contact between the mem-
the power station [3]. The current work requirement is reported to brane material and flue gas. On the contrary, the three-end concept
be 220 kWh/tO2 by Foster Wheeler [22] and 245 kWh/tO2 from Hong [28,29] illustrated in Fig. 3(b) seems to be an attractive option, in
et al. [23] for the large-scale production of several thousand tons which direct contact between the membrane and flue gas can be
of oxygen needed by oxyfuel process. For a standalone system, the avoided. In this particular case, the oxygen is extracted from the
energy demand for the production of oxygen is about 240 kWh/tO2 , membrane module by a vacuum pump. It is worthwhile to be noted
which causes the overall plant efficiency to decrease to about 8–10% that although higher thermal efficiency of the oxyfuel combustion
points [24]. The improvement of heat recovery from the cryogenic process is obtainable if the first concept is employed, the three-end
unit separation process as well as the optimization of the separation concept is likely to be more feasible because there are no mem-
process could reduce the energy demand to 160 kWh/tO2 [19]. brane materials are available that can withstand the direct contact
The second method for the production of oxygen from air with the flue gas; therefore, the development of membrane materi-
separation is by using novel ceramic membranes with MIEC char- als is very crucial [30,31]. Kneer et al. [25] successfully presented in
acteristics. Fig. 2 illustrates the schematic of an oxyfuel combustion their paper on membrane-based air separation modules and their
power plant incorporating MIEC membrane. As shown in Fig. 2, air design for oxycoal conditions, the specifications of coal combustion
compressor functions to pressurize the air up to 10 bar. In order in a CO2 /O2 atmosphere including related burner design as well as
to obtain the separation of air, both membrane and air have to be the cleaning of hot flue gas from oxycoal combustion.
exposed to temperatures above 800 ◦ C and an oxygen partial pres- It is worth being noted that there are issues related to the imple-
sure ratio across the membrane has to be applied as well. The heat to mentation of this novel method for the oxygen supply from air
bring this high temperature can be extracted from the combination separation. First, the membrane separation system has to be oper-
of compression of the air, flue gas recycle and also heat exchange ated at temperatures above 900 ◦ C in order to deliver high oxygen
from the boiler. Interestingly, the ceramic membrane module can permeation flux. As a result, there will be large energy penalties
be integrated at the front end of the oxyfuel combustion plant. One in this process because the heated air contains about 80% (v/v)
of the technical features of such integration is the use of recycled of nitrogen, as a waste gas. The energy losses can be reduced
CO2 from the combustion process could lead to a high oxygen driv- through proper implementation of the heat recovery, although the
ing force resulting from the constant oxygen partial pressure drop process efficiency losses can never be completely recovered. Sec-
across the membrane. The oxygen permeates selectively through ondly, although high CO2 partial pressure is practically attractive
a membrane, from the compressed air side into the recycled CO2 to membranes due to the high oxygen driving force, the aggressive
stream, enriching it to about 20% (v/v) [3]. Thereafter, the oxy- conditions would cause these membrane materials to destabilize;
gen enriched CO2 stream can be burnt directly in the boiler that thus, their performance in producing oxygen for the oxyfuel com-
will yield the superheated steam to drive the steam turbines and bustion process will be limited. It is expected that the large demand
subsequently, produce electricity. for oxygen supply for oxyfuel combustion process in the near future
There are two different concepts for incorporating MIEC mem- will result to the implementation of oxygen membrane separation
brane into the oxyfuel combustion process, as illustrated in Fig. 3. technology; however, ongoing research and development is crucial
As shown in Fig. 3(a), the concept of allowing the flow of recircu- to overcoming the major hurdles. In brief, a significant cost reduc-
1288 S.S. Hashim et al. / Renewable and Sustainable Energy Reviews 15 (2011) 1284–1293

Fig. 3. Schematic of membrane for oxygen separation in oxyfuel processes using (a) four-end concept and (b) three-end concept [31].

tion in the oxygen production causes the oxyfuel power plant as an carriers as alternative methods to produce oxygen has also been
attractive option when the carbon capture becomes a requirement studied, which includes the close cycle looping of CaSO4 [35,36]
in the future. Hence, it is believed that ceramic membranes are an and other oxygen carriers such as manganese [37], nickel [38] and
effective high temperature air separation technique that may offer iron [39,40] oxides. Nevertheless, there are problems of employing
a considerable cost reduction in the production of oxygen for this this particular method such as slow reaction rates, solid handling
particular application. and large solid oxygen carrier inventory [39,40]. The introduction
of novel method based on ceramic membranes for oxygen produc-
2.2. Gasification systems tion from air separation is believed to increase the efficiency of IGCC
power plant because these membrane modules involve no moving
Gasification is an energy extraction method that converts rela- parts; thus, it is easy to operate and maintain. Fig. 4 illustrates the
tively low cost feedstocks such as coal, natural gas petroleum coke incorporation of the ceramic membrane and coal gasification in
in isolated or geographically unfavorable sites, biomass or organic an IGCC plant. It should be noted that the syngas produced by the
waste. The reaction of these feedstocks with a controlled amount gasifier is used as fuel in the gas turbine and the heat generated by
of oxygen and/or steam at high temperatures produces synthesis the combustion is used to generate steam to drive the steam tur-
gas (syngas), which consists of carbon monoxide (CO) and hydro- bine. Meanwhile, the turbine that functions to run the generator
gen (H2 ). Subsequently, the produced syngas stream is fired in can be used to supply compressed air to the membrane unit while
a combined-cycle power plant. The combined-cycle power plant the steam from the steam turbine can be sent directly to the mem-
uses one or more gas turbines and steam turbines in series to gen- brane unit. Unlike the membrane operated in oxyfuel plant that
erate electricity. Electricity generation using gasification is called must be resistant to the reducing effects of CO2 in the permeate
integrated gasification combined cycle (IGCC). The syngas can also
be further refined to yield a variety of petrochemical products in
a coal-to-liquid (CTL) plant, or by catalytically reacting the syn-
gas using Fisher–Tropsch synthesis in a gas-to-liquid (GTL) plant
to produce liquid transportation fuels, such as naphtha, jet fuel
and low-sulfur diesel. The heart of any gasification-based facility
is the partial oxidation reactor where the reaction of the feedstock
with a high-pressure oxygen stream to produce the syngas occurs.
Hence, the gasification technique is fundamentally relied on the
use of pure oxygen. Large-scale commercial gasification facilities
require an enormous amount of oxygen, which lead to the technol-
ogy requirements to meet the large oxygen demand.

2.3. Coal gasification

The technical advantages of coal gasification for power genera-


tion include its high efficiency and low emissions of SOx , NOx and
particulate matter. It is to be noted that an IGCC coal-fired power
plant comprises of two technologies, which are coal gasification and
combined cycle that leads to the most efficient method for elec-
tricity generation [32,33]. Traditionally, the oxygen feed for coal
gasification is carried out by cryogenic distillation method; how-
ever, it has been reported that there are several inefficiencies by Fig. 4. Incorporation of coal gasification and MIEC membrane module in an IGCC
using this conventional technology [34]. The use of solid oxygen power plant [3].
S.S. Hashim et al. / Renewable and Sustainable Energy Reviews 15 (2011) 1284–1293 1289

Natural Gas gen partial pressure on the fuel side of the membrane is on the
Methane order of 10−12 –10−16 units regardless of the fuel side total pres-
Gas Processing sure, a substantial driving force is established across the membrane
CO [43]. Additionally, by membrane-based separation, the need for air
Syngas Fisher
Production Tropsch
compression is minimized; sufficiently enough to overcome the
H2 pressure drop through the membrane separation unit and air heat
Air Separation
Oxygen Synthetic Crude exchangers. A considerable attention has to be focused on the mem-
brane stability to withstand the extreme temperatures and stresses
Air LPG Product of an ATR environment, as well as their resistance to the creep,
Naphtha Refining corrosion and poisoning [43]; also, the long term compatibility
Diesel
with the reduction and reforming catalysts. Besides, the oxidation
Fig. 5. Main steps in the commercial GTL process [42]. process on the fuel side is very rapid and exhibits the so-called
autocatalytic effect that reduces the oxygen partial pressure and
increases the temperature, which leads to the increase in the oxy-
side, the membrane used in coal gasification plant must be resis- gen permeation flux. Therefore, it is necessary to control the partial
tant to steam; so that, the heat from the steam does not affect the oxidation exotherm by providing a stable thermal operating mode
membrane applications [41]. In a nutshell, the use of MIEC mem- and control mechanisms to avoid thermal runways and formation
branes in coal gasification systems has a promisingly potential for of hot spots. It is to be noted that MIEC ceramic membranes could
the production of tonnage supply of oxygen from air separation if replace the conventional cryogenic distillation by offering cheaper
further research is directed to overcome the design and engineer- and higher efficiency technology for the production of syngas from
ing problems related to these membrane materials and gas tight natural gas for ultra-clean fuel applications if problems related to
sealing of the membranes in the modules. membrane incompatibility are solved.

2.4. Gas-to-liquid (GTL) process


3. Progress in high temperature membrane-based
Gas-to-liquid (GTL) technology converts natural gas to clean and separation for oxygen production
useful liquid hydrocarbons, suitably to overcome problems such as
remote gas utilization, crude oil price and environmental pollution 3.1. Advanced zero emissions power plant (AZEP) project
[42]. Fig. 5 shows the main steps in the commercial GTL process,
which are: (1) air separation, (2) gas processing, (3) syngas pro- Prior to the Griffin et al. [44] work, the most efficient and
duction, (4) Fisher–Tropsch (FT) synthesis, (5) hydrocracking and cost-effective utilization of the MIEC membrane reactor is by inte-
(6) product separation. Autothermal reforming (ATR) is a conven- grating it into a conventional gas turbine system to initiate an
tional syngas technology for FT process that requires high purity advanced zero emissions plant, namely an AZEP concept. The aim
oxygen, which is traditionally produced by the cryogenic distilla- of this project is to replace a gas turbine-based power genera-
tion process. However, the large cryogenic distillation consumes tion process to reduce CO2 emissions by an oxyfuel system using
10–15% of the total capital costs. An enormous power demand MIEC membrane with natural gas fuel [45]. The core element in
to carry out compression and chilling is required. The introduc- AZEP is an integrated MIEC membrane reactor [46], which involves
tion of ceramic membranes to replace the conventional cryogenic three steps: (1) the separation of oxygen from air using MIEC
distillation method is considered as an attractive option for the pro- membrane, (2) the combustion of natural gas in a nitrogen-free
duction of oxygen from air separation at high temperatures. This environment and (3) the heat of combustion is transferred to air
novel technology significantly reduces the capital costs as well as by heat exchange. The required heat to operate MIEC membrane is
offers high efficiency method to produce syngas from the natural supplied by the heat generated from this combustion; thereafter,
gas. Fig. 6 illustrates the schematic of syngas production process. the oxygen depleted air that leaves the reactor is heated from this
As shown in Fig. 6, the membrane structure incorporates the dense combustion. The design of the MIEC membrane reactor is a combi-
ceramic membrane undergoing reduction containing reforming nation of square section multichannel extruded ceramic monolith
catalyst. The ceramic membranes are attractive because oxygen heat exchange and ion transport membrane (ITM). The membrane
permeates from low pressure side to high pressure fuel stream material used is a mixed metallic oxide that could withstand the
without the need of mechanical compression. Because of the oxy- combustion temperature of 1300 ◦ C [7]. Fig. 7 demonstrates the
simplified sketch of the AZEP concept. The process exhaust com-
prises of two separate flows, which are oxygen-depleted air flow
and CO2 and H2 O flow, in which the CO2 can be sending off for
end disposal by condensing the water. The combustion products on
the permeate side, which are mostly of CO2 and H2 O are partially
recirculated into the reactor and partially expanded in the “sweep
turbine” for additional power generation. Moller et al. [47] did a
thermo-economic analysis on the AZEP gas turbine combined cycle
power plants. These researchers concluded that uncertainties in the
MIEC membrane reactor cost and useful life of ceramic membrane
materials do not have an immense influence on the electricity cost.
Hence, towards the reduction of CO2 avoided cost, the AZEP con-
cept is believed to be more fuel efficient than the baseline system
[7]. It is noticeable that there is a problem of using ceramic mem-
branes to supply oxygen; the ceramic membranes cannot be heated
to too high temperature because it may cause these membranes to
Fig. 6. The synthesis gas production incorporates the dense ceramic membrane and destabilize; however, in order for the gas turbine to achieve high
reduction and reforming catalyst [14]. efficiency, the combustion process should occur at the highest pos-
1290 S.S. Hashim et al. / Renewable and Sustainable Energy Reviews 15 (2011) 1284–1293

Fig. 7. A schematic of an AZEP concept [48].

sible temperature. As a summary, it is important to develop both 3.3. OXYCOAL-AC project at RWTH Aachen University
membranes and high temperature heat exchanger for a successful
AZEP concept. Six research institutes at Rheinisch-Westfälische Technische
Hochschule Aachen (RWTH Aachen University) and five industry
3.2. Zero emission ion transport membrane oxygen power partners worked cooperatively since September 2004 to develop a
(ZEITMOP) free CO2 -emission oxycoal combustion power plant incorporating
MIEC membrane for electricity generation [52]. This OXYCOAL-AC
Yantovski et al. [49] proposed Zero Emission Ion Transport project is based on pulverized coal combustion in a CO2 /H2 O/O2
Membrane Oxygen Power (ZEITMOP), using MIEC membrane to atmosphere and targeted high CO2 concentrations in the flue gas
extract the oxygen required for combustion from air. The ZEITMOP for subsequent CO2 capture and storage [52]. Fig. 8 shows the
cycle requires a membrane unit that operates at 920 ◦ C and a sepa- key component of this concept is ion transport membrane for
rate combustion chamber that operates at 1400 ◦ C. Physically, the oxygen production where oxygen molecules are transferred from
air separation unit could be smaller if oxygen is consumed by a the pressurized air side across a mixed conducting membrane to
chemical reaction on the permeate side if the membrane whence the recirculated low pressure flue gas stream [52]. The scope of
the large oxygen flux is obtainable. Besides, no additional heating this project includes screening and testing of available membrane
is required if this reaction is exothermic where the air separa- materials, especially perovskites; advanced manufacturing pro-
tion unit is heated by the reaction itself. Interestingly, these two cesses for tubes and discs as well as searching for relevant material
requirements are fulfilled by combustion; hence, combustion in properties for their applicability to oxycoal conditions. Accordingly,
the membrane module would permit a smaller air separation unit, MEM-OXYCOAL was initiated in 2006 focusing on the development
which would also act as a combustion chamber. However, most of membrane materials for the OXYCOAL-AC process [52]; there-
membranes are easy to get damaged as the combustion cham- after, a comprehensive analysis on varying thermal, mechanical and
ber operates at 1400 ◦ C. Since the worldwide expectations towards chemical conditions can be possibly done; and, module geometry
oxygen separation membranes are extremely high, an extensive can also be properly designed, which are still under development.
research is continually engaged in developing new materials; The detailed information on the design of the membrane reactor
therefore, it may be possible to have an oxygen membrane chamber for the OXYCOAL-AC cycle is well-discussed by Renz et al. [53]. It
operating at 1400 ◦ C. Additionally, the combustion chamber may be is noted that the commercialization of this particular process is
cooled, so that it could operate at more realistic temperatures for possible through the ongoing developments of oxygen separation
current available membrane materials. A comprehensive analysis
of the effects of combining air separation with combustion in a ZEIT-
MOP was presented by Foy and McGovern [50]. These researchers
concluded that the use of a combined ion transport membrane oxy-
gen combustion chamber and air separation unit in the ZEITMOP
cycle did not perform well, unless the unit can be operated at high
temperatures. In addition, the use of a high temperature combined
ion transport oxygen combustion chamber and air separation unit
appears brought only minor effect on the thermodynamic efficiency
of the ZEITMOP. Furthermore, further investigation of the effect
of combining the two units must be done by simulating the heat
exchange between the combustion and air streams in the combined
unit. The optimization of the ZEITMOP cycle could help to increase
its efficiency since this particular cycle is not commercially avail-
able yet. Since all types of fossil fuels are suitable for this cycle [51],
it is believed to be one of the attractive options for the development
of zero CO2 -emission fossil fuel-based power plants. Fig. 8. Schematic of an OXYCOAL-AC power plant process [25].
S.S. Hashim et al. / Renewable and Sustainable Energy Reviews 15 (2011) 1284–1293 1291

membranes as well as proper design concepts for scaling up the Therefore, it can be said that the integration of the MIEC mem-
membrane modules and their integration into pilot or power plant brane air separation unit in the oxyfuel process is technically more
scale facilities. advantageous in comparison to the IGCC process with respect to the
pressure operating conditions. It is also crucial to consider the issue
of membrane materials for the production of oxygen from air sep-
4. Critical issues in the implementation of aration for power generations and fuel production. The challenges
membrane-based separation technology for oxygen that are needed to be overcome are to ensure that these membranes
production in the power generation and fuel production have high permeability, specific selectivity and long-term stability
up to 100,000 h [56]. It is noticeable that the availability of mem-
The energy demand for oxygen production is one of the major branes for used gas separation in other fields such as in chemical
reasons for the efficiency losses in implementing carbon capture industry is not yet reached its level of suitability for large-scale
and storage (CCS) based on oxyfuel combustion system as well industrial applications as required in power generation and fuel
as gasification systems. Hence, the membrane separation technol- production. Therefore, it is important to come out with remark-
ogy based on ceramic membrane material is adopted to replace able strategies for these ceramic MIEC membranes with regards to
the conventional cryogenic separation technology. However, there materials science and technology into the research and technology
are several issues that need to be addressed. One of the issues in development. Conclusively, membrane operating conditions and
implementing high temperature MIEC membrane air separation is membrane materials are related to each other. Membrane materi-
the large penalty associated with heating the air up to 900 ◦ C for the als used must be compatible to the process conditions; hence, the
membrane to operate. Another issue is the current instability of the implementation of ceramic membranes for oxygen production in
membrane material with reducing and extreme environments [3]. power generation and fuel production can be fully utilized in the
The energy demand for the production of oxygen by ceramic- power generation and fuel production applications.
based membrane air separation is determined by the required high
temperature heat [54]. It is crucial to note that there will be a large
energy penalty associated with high air volume heating, as the max- 5. The way forward
imum theoretical recovery rate is the concentration of oxygen (21%)
in an air; thus, to operate the high temperature ceramic membrane- Presently, membrane separation is a new technology in compar-
based air separation unit, these membranes have to be heated ison to the well-matured cryogenic air separation in the production
well, typically at 700–1100 ◦ C. Although some of the energy can be of oxygen from air separation for power generation and fuel
recovered from the waste gases, the process efficiencies could be production purposes; namely, oxyfuel combustion process, coal
improved with the recovery of energy. As for coal-fired power plant, gasification systems as well as syngas production. Importantly, the
the heat required is supplied by the flue gases. In Oxycoal-AC pro- heart of the membrane-based separation at high temperatures is
cess, the flue gas provides the required high temperature heat and the membrane materials that are exclusively stable, strong, and
also enhances the oxygen permeation flux by sweeping the mem- creep resistant and with high oxygen flux. Therefore, it is expected
brane. To supply high temperature heat up to 700 ◦ C, about 70% of that there will be improvements in the performance of membrane
the flue gas is fed to the membrane separation unit; thereafter, it in oxidizing and reducing environments. Moreover, there will be a
is recycled to the combustion chamber at the temperature around focus on long term membrane materials testing programs, which
500–700 ◦ C after oxygen enrichment. One of the major problems is will emphasize on the pressure and temperature cycling to exploit
that the membrane material may be destabilized or incompatible these membranes useful life. The mentioned vision will only be
to high temperature gas cleaning unit for removal of dust and flue realized through extensive research and development (R&D). Even-
gas components; moreover, the recirculation fan should operate in tually, there is a need to develop reasonable demonstration-scale
the high temperature, ranging from 500 to 700 ◦ C. Therefore, the projects under practical operating conditions to obtain the remark-
effect of the hot end flue gas recirculation fan on the overall power able oxygen production required by the industry. The so-called
plant efficiency should be accounted. Furthermore, although the MEM-BRAIN project’s primary objective is to pool the expertise of
high temperature of the gases is useful to provide a better gas tur- scientists and engineers that includes improving the membrane
bine power output in the process, more energy is definitely required performance, to analyze the technical requirements for optimal
for the permeate recompression due to the higher quantity of this use during operation and also to define targets for the develop-
stream. Pfaff and Zwick [55] analyzed that the oxyfuel process with ment of the membrane system [56]. Consequently, it is believed
high temperature membrane air separation unit shows the depen- that the continuous cooperative research and development work
dency on the heat recovery of the off-gas leaving the expansion would lead to the clear identification of the optimal membrane
turbine. These researchers claimed that it is irrelevant to minimize development approaches for the long-term applications in reduced
the thermal and electrical energy demand to run this particular air time operation.
separation unit for overall process optimization purposes. Accord- The size of the membrane module unit for an oxyfuel power or
ing to these researchers, it is also inevitable for a minimal degree coal gasification plant should be as small as feasible for the techni-
of the integration of ceramic membrane with regards to the heat cally and economically purposes [3]. A considerable attention has
recovery to compete with the net efficiency of the oxyfuel process to be directed to the required membrane surface area because the
with the conventional cryogenic separation (oxygen purity 99.5%, membrane surface area increases with lowered differential oxy-
v/v) without any integration. The application of high temperature gen partial pressure, which is equivalent to the increase of oxygen
MIEC ceramic membrane-based air separation is dependent on the recovery rate and decrease of compressor outlet pressure. There are
process [3]. It is questionable, at a different pressure operating con- several conceptual options available and these include monolithic
dition, which process incorporating MIEC membrane for oxygen tubes [55], hollow fiber membranes [57], honeycomb structures
production results to less energy demand. The integration of the [58], and planar arrangements [59]. Schiestel et al. [57] suggested
MIEC membrane unit requires the oxyfuel combustion system to hollow fiber membrane modules for their high packing density
be operated at ambient pressure operating conditions, while IGCC and high flux features; at the same time, the engineering parame-
process at elevated pressures. Obviously, the IGCC incorporating ters must be accounted for scaling up technology purpose because
MIEC membrane is an energy intensive process due to the com- they are relatively fragile and difficult to seal. The design of scale
pression of oxygen until the gasifier pressure level is achieved. up modules for oxygen separation where tubes were favored over
1292 S.S. Hashim et al. / Renewable and Sustainable Energy Reviews 15 (2011) 1284–1293

the hollow fibers or flat plate multi-channel monoliths has been research should be directed to the chemical and thermal stabil-
demonstrated by Vente et al. [60]. The ion transport membrane ity of the membrane, membrane geometries as well as sealing
using a flat membrane with wafer configuration module operat- technology. Moreover, there is a need from the pools of scien-
ing at 800–900 ◦ C is well-developed by Air Products and Chemicals tific and engineering community to investigate the impact of high
[61]. Norsk Hydro is developing composite multi-channel heat temperature membrane operation to the overall efficiency and the
exchanger plus membrane modules in extruded ceramics oper- energy requirement for the technology could be employed for the
ating at temperatures up to 1300 ◦ C while Praxair uses tubes at tonnage production of oxygen from air separation, replacing the
800–900 ◦ C [7]. It is worth being noted that it is also difficult to energy-intensive; conventional air separation technologies. There-
seal multi-channel monoliths, in particular when small channels fore, it is expected that the oxygen separation from air by using
are employed to maximize the membrane surface area, while it is ceramic-based membrane technology will be implemented in the
less difficult for sealing single tube configurations. The use of glass near future for its promisingly potential for sustainable energy
ceramic seals that consist of boro-silicate glass has been adopted delivery, fuel production and a cleaner environment.
[62]; however, the seals must be well-designed for each application
and prone to be extremely brittle [3]. A comprehensive review on
the material choice, membrane and module design, seal develop- Acknowledgements
ment and fabrication issues has been presented by den Exter et al.
[63] in their paper. The authors gratefully acknowledge financial support by the
For the integration of high MIEC membrane into the oxyfuel Ministry of Science, Technology and Innovation, Malaysia (E-
coal-fired combustion system, the improvement of the individual Science grant) as well as by the Universiti Sains Malaysia (Research
efficiencies is emphasized towards improving the overall system University grant).
efficiency [31]. Stadler et al. [31] claimed that the increase of pres-
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