Solid multi-component membranes, electrochemical reactor components, electrochemical reactors and use of membranes, reactor components, and reactor for oxidation reactions

Abstract

Solid membranes comprising an intimate, gas-impervious, multi-phase mixture of an electronically-conductive material and an oxygen ion-conductive material and / or a mixed metal oxide of a perovskite structure are described. Electrochemical reactor components, such as reactor cells, and electrochemical reactors are also described for transporting oxygen from any oxygen-containing gas to any gas or mixture of gases that consume oxygen. The reactor cells generally comprise first and second zones separated by an element having a first surface capable of reducing oxygen to oxygen ions, a second surface capable of reacting oxygen ions with an oxygen-consuming gas, an electron-conductive path between the first and second surfaces and an oxygen ion-conductive path between the first and second surfaces. The element may further comprise (1) a porous substrate, (2) an electron-conductive metal, metal oxide or mixture thereof and / or (3) a catalyst. The reactor cell may further comprise a catalyst in the zone which comprises a passageway from an entrance end to an exit end of the element. Processes described which may be conducted with the disclosed reactor cells and reactors include, for example, the partial oxidation of methane to produce unsaturated compounds or synthesis gas, the partial oxidation of ethane, substitution of aromatic compounds, extraction of oxygen from oxygen-containing gases including oxidized gases, ammoxidation of methane, etc. The extraction of oxygen from oxidized gases may be used for flue or exhaust gas cleanup.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS [0001] This patent application is a continuation-in-part of U.S. patent application Ser. Nos. 07 / 457,327 filed on Dec. 27, 1989; 07 / 457,340 filed on Dec. 27, 1989, which is a continuation-in-part of U.S. patent application Ser. No. 07 / 25,511 filed on Mar. 13, 1987 and issued as U.S. Pat. No. 4,933,054 on Jun. 12, 1990; Ser. Nos. 07 / 457,384 filed on Dec. 27, 1989; and 07 / 510,296 filed on Apr. 16, 1990, which is a continuation-in-part of U.S. patent application Ser. No. 07 / 357,317 filed on May 25, 1989, now abandoned, which are hereby fully incorporated herein by reference.TECHNICAL FIELD [0002] This invention relates to the field of electrochemical reactors which facilitate the transfer of oxygen. In particular, this invention relates to oxygen semipermeable membranes, components for electrochemical reactors comprising the oxygen semipermeable membrane, electrochemical reactors and reactor components comprising the oxygen semipermeable membrane...

AI Technical Summary

Benefits of technology

The present invention is related to a solid multi-component membrane for use in electrochemical processes. The membrane is made up of an electronically-conductive phase and an oxygen-ion conductive phase, and can be used in electrochemical reactors. The membrane can also contain a catalyst. The invention also includes an electrochemical reactor cell for reacting oxygen-containing gas with oxygen-consuming gas. The process involves heating the reactor cell and passing the gases through separate zones for reaction. The invention also includes an electrochemical process for oxidizing methane, natural gas, or other light hydrocarbons to unsaturated hydrocarbons or synthesis gas.

Problems solved by technology

As a result of the high temperatures required, rates of competing cracking and coking reactions are high enough to adversely affect product selectivities.

Conventional oxydehydrogenation processes, which are not inherently equilibrium limited, also suffer from poor product selectivities at high ethane conversions.

Sulfur oxides are known to combine with water vapor to form a highly corrosive vapor causing irritation to eyes and mucous membrane, damage to metal-containing structures, and environmental harm to vegetation due to acid rain.

Nitrogen oxides are toxic irritants and are also damaging to the environment.

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