# US 10,441,922 B2 · Dual function composite oxygen transport membrane > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 10,441,922 B2 - Document ID: US10441922B2 - Status: Granted - Kind: B2 - Application number: 14/753,815 - Filed: 2015-06-29 - Published: 2016-12-29 - Granted: 2019-10-15 - Earliest claimed: 2015-06-29 - Assignees: Praxair Technology, Inc. - Applicants: Jiefeng Lin; Pawel Plonczak; Sean M. Kelly; Uttam R. Doraswami; Jonathan A. Lane - Inventors: Jiefeng Lin; Pawel Plonczak; Sean M. Kelly; Uttam R. Doraswami; Jonathan A. Lane - Web page: https://patentgrep.com/patent/US10441922B2 ## CPC - B01D 71/02231: {Palladium} - B01D 67/0039: {Inorganic membrane manufacture} - B01D 67/0048: {by sol-gel transition} - B01D 69/04: Tubular membranes - B01D 69/108: {Inorganic support material} - B01D 69/1216: {Three or more layers} - B01D 71/0271: {Perovskites} - B01J 23/462: {Ruthenium} - B01J 23/892: {Nickel and noble metals} - B01J 35/59: Membranes - B01J 37/0215: {Coating} - B01D 53/228: {characterised by specific membranes} - B01D 2311/2696: Catalytic reactions - B01D 2325/10: Catalysts being present on the surface of the membrane or in the pores - B01D 2325/20: Specific permeability or cut-off range - Y02E 60/50: Fuel cells - B01D: SEPARATION (separating solids from solids by wet methods B03B, B03D; by pneumatic jigs or tables B03B; by other dry methods B07; magnetic or electrostatic separation of solid materials from solid materials or fluids, separation by high-voltage electric fields B03C; centrifuges, vortex apparatus B04; presses per se for squeezing-out liquid from liquid-containing material B30B9/02; treatment of water C02F, e.g. softening by ion-exchange C02F1/42; {arrangements of air intake cleaners in gas turbine plants F02C7/05} ; arrangements or mounting of filters in air-conditioning, air-humidification or ventilation F24F13/28) - B01J: CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS - Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION ## Abstract A dual function composite oxygen transport membrane having a layered structure of mixed conducting oxygen transport materials on a first side of a porous substrate and a reforming catalyst layer on an opposing second side of the porous substrate. The layered structure of the mixed conducting oxygen transport materials contains an intermediate porous layer of mixed conducting oxygen transport materials formed on the porous substrate with a dense impervious layer of mixed conducting oxygen transport materials over the intermediate porous layer, and an optional surface exchange layer of mixed conducting oxygen transport materials over the dense impervious layer. The layered structure and the reforming catalyst layer are formed in separate steps. ## Claims ### Claim 1 A dual function composite oxygen transport membrane, said dual function membrane comprising: a porous substrate having a first side and an opposing side, a plurality of mixed conducting oxygen transport layers, and a catalyst layer for catalyzing endothermic reactions, wherein the plurality of mixed conducting oxygen transport layers are formed on the first side of the porous substrate and the catalyst layer is coated on the opposing second side of the porous substrate, wherein a thickness of the catalyst layer is at least 10 microns. ### Claim 2 (depends on 1) The dual function composite oxygen transport membrane of claim 1 wherein said plurality of mixed conducting oxygen transport layers form a layered structure comprising a dense layer, an intermediate porous layer located between the dense layer and the porous substrate, and an optional surface exchange layer over the dense layer wherein each of the dense layer and the intermediate porous layer and the surface exchange layer are capable of conducting oxygen ions and electrons at operational temperatures. ### Claim 3 (depends on 2) The dual function composite oxygen transport membrane of claim 2 wherein said layered structure formed on the first side of the porous substrate separates oxygen from an oxygen containing gas stream in contact with the layered structure when operational at operational temperatures and provide said separated oxygen for reaction with a combustible substance diffusing through the catalyst layer formed on the opposing second side of said porous substrate. ### Claim 4 (depends on 1) The dual function composite oxygen transport membrane of claim 1 wherein, the thickness of said catalyst layer is in the range of about 40 microns to about 80 microns. ### Claim 5 (depends on 1) The dual function composite oxygen transport membrane of claim 1 wherein the catalyst layer contains one or more of nickel, rhodium, platinum, ruthenium, or palladium. ### Claim 6 (depends on 1) The dual function composite oxygen transport membrane of claim 1 wherein the catalyst layer is formed using precursors of nickel or rhodium or platinum or ruthenium or palladium or mixtures of two or more thereof. ### Claim 7 (depends on 1) The dual function composite oxygen transport membrane of claim 1 wherein the catalyst layer is formed using a perovskite material containing Ruthenium. ### Claim 8 (depends on 1) The dual function composite oxygen transport membrane of claim 1 further comprising the porous substrate configured as a substantially tubular structure wherein the plurality of mixed conducting oxygen transport layers are formed on the outside surface of said tubular structure and the catalyst layer is formed on the inside surface of said tubular structure. ### Claim 9 A method of forming a dual function composite oxygen transport membrane, said method comprising: providing a porous substrate having a first side and an opposing second side; forming a layer structure of mixed conducting materials in a sintered state on the first side of the porous substrate, coating a catalyst layer on the opposing second side of the porous substrate for catalyzing endothermic reactions, wherein a thickness of the catalyst layer is at least 10 microns. ### Claim 10 (depends on 9) The method of claim 9 wherein the layered structure of mixed conducting materials comprises an intermediate porous layer, a dense layer, and an optional surface exchange layer, and the forming of the dense layer and the forming of the catalyst layer is carried out in separate steps. ### Claim 11 A method of forming a dual function composite oxygen transport membrane, said method comprising: providing a porous substrate having a first side and an opposing second side; forming an intermediate porous layer on the first side of the porous substrate; forming a dense layer over the intermediate porous layer, forming a surface exchange layer over the dense layer, and coating a catalyst layer on the opposing second side of the porous substrate, wherein a thickness of the catalyst layer is at least 10 microns. ### Claim 12 (depends on 11) The method of claim 11 wherein the coating of the catalyst layer is carried out after the forming of the surface exchange layer. ### Claim 13 (depends on 11) The method of claim 11 wherein a catalyst layer coating step in the coating of the catalyst layer is carried out prior to a high temperature sintering step in the forming of the surface exchange layer. ### Claim 14 (depends on 11) The method of claim 11 wherein a catalyst layer coating step in the coating of the catalyst layer is carried out prior to a coating step in the forming of the surface exchange layer. ### Claim 15 (depends on 11) The method of claim 11 wherein a catalyst layer coating step in the coating of the catalyst layer is a wash-coating technique.