The integration of oxygen separation membranes in industrial processes can bring both energy and economic advantages, but demonstrating the feasibility of this technology requires developing membrane module prototypes. This work describes the development of a laboratory-scale module through a comprehensive study that considers all relevant technological aspects to create a prototype ready for testing in an industrial environment.

In particular, planar components of La0.6Sr0.4Co0.2Fe0.8O3-δ have been fabricated suitable for both 3-end and 4-end operations, using a scalable technique and designing them with geometry ensuring a fracture probability under real operational conditions of 2.2 * 10-6. The asymmetric membranes enabling oxygen separation showed a permeation rate of approximately 3 NmL/min/cm2 at 900°C in air/He gradient, with significant stability up to 720 h. Permeation results were used to develop a CFD model describing the influence of working conditions on module performance. The membrane component housing is an Inconel 625 casing joined to the ceramic component by a specially developed glass-ceramic sealant showing remarkable thermochemical compatibility with both the metal and ceramic, despite high-temperature chemical expansions of LSCF.

The multidisciplinary approach adopted in this work can be adapted to other types of membrane-based modules with different sizes, configurations, and materials.