Process for separating oxygen from an oxygen-containing gas by using a bi-containing mixed metal oxide membrane

Claim 2

A process for separating oxygen from a first oxygen-containing gas, the process comprising: (A) Feeding the first oxygen-containing gas into a first zone of a gas separation apparatus, the apparatus comprising first and second zones separated by a mix metal oxide membrane, the membrane having a first surface open to the first zone, a second surface open to the second zone, and an empirical formula of Bi A.sub.x M.sub.y M'.sub.z O.sub.n where A is at least one of La, U, Th, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Lu, Y, Mg, Ca, Sr and Ba; M is at least one of Sc, Ti, Cr, Mn, Fe, Ni, Cu and Zn; M' is at least one of Co, Rh, Pd, Pt and Ru; x and y are individually a number between about 0.01 and about 10; z is a number of 0 to about 0.2; and n is a number that satisfies the valence requirements of the other elements present; the first zone having an equilibrium oxygen partial pressure greater than that of the second zone; (B) Contactiong the first oxygen-containing gas in the first zone of the separation apparatus with the first surface of the membrane such that: (i) oxygen is extracted from the first oxygen-containing gas at the first surface of the membrane; and (ii) the extracted oxygen is transported across the membrane, in the form of oxide ions, to the second surface of the membrane; and (C) Reacting the extracted oxygen present on the second surface of the membrane with an oxygen-consuming substance that is present in the second zone and is in contact with the second surface of the membrane.

Claim 3

The process of claim 1 where x is a number between about 0.2 and about 5, and y is a number between about 0.2 and about 7.

Claim 4

The process of claim 1 where x is a number between about 0.5 and about 2, y is a number between about 0.5 and about 3, and z is a number greater than 0.

Claim 5

The process of claim 2 where A is at least one of La, Ca, Y, Ba, Ce, U and Gd, M is at least one of Fe, Cu, Cr and Ni, and M' is at least one of Co, Rh, Pd and Ru.

Claim 6

The process of claim 2 where A is at least one La, Ca and Ba, M is at least one of Fe, Ni and Cr, and M' is at least one of Co, Ru and Pd.

Claim 7

The process of claim 4 where at least a portion of the oxygen in the first oxygen-containing gas is molecular oxygen.

Claim 8

The process of claim 4 where the first oxygen-containing gas comprises at least one of air, sulfur dioxide and a nitrogen oxide.

Claim 9

The process of claim 4 where the first oxygen-containing gas comprises air.

Claim 10

The process of claim 7 where the oxygen-consuming substance comprises at least one of hydrogen gas, a hydrocarbon gas, and a gaseous carbon monoxide/carbon dioxide mixture.

Claim 11

The process of claim 7 where the membrane is used in the absence of a support.

Claim 12

The process of claim 7 where the membrane is used in combination with a support.

Claim 13

The process of claim 9 or 10 where the temperature of each zone is between about 300° and about 900° C.

Claim 14

The process of claim 9 or 10 where the temperature of each zone is between about 400° and about 800° C.

Claim 15

The process of claim 9 or 10 where the second oxygen-containing gas is removed from the second zone by a sweep gas.

Claim 16

The process of claim 1 where the extracted oxygen is recovered from the second surface of the membrane in the form of molecular oxygen.

Claim 17

The process of claim 15 where x is a number between about 0.2 and about 5, and y is a number between about 0.2 and about 7.

Claim 18

The process of claim 15 where x is a number between about 0.5 and about 2, y is a number between about 0.5 and about 3, and z is a number greater than 0.

Claim 19

The process of claim 16 where A is at least one of La, Ca, Y, Ba, Ce, U and Gd, M is at least one of Fe, Cu, Cr and Ni, and M' is at least one of Co, Rh, Pd and Ru.

Claim 20

The process of claim 16 where A is at least one of La, Ca and Ba, M is at least one of Fe, Ni and Cr, and M' is at least one of Co, Ru and Pd.

Claim 21

The process of claim 18 where the first oxygen-containing gas comprises molecular oxygen.

Claim 22

The process of claim 18 where the first oxygen-containing gas comprises at least one of air, sulfur dioxide, and a nitrogen oxide.

Claim 23

The process of claim 21 where the membrane is used in the absence of a support.

Claim 24

The process of claim 21 where the membrane is used in combination with a support.

Claim 25

The process of claim 21 where the temperature of zone 1 is between about 300° and about 900° C.

Claim 26

The process of claim 21 where the temperature of zone 1 is between about 400° and about 800° C.

Claim 27

The process of claim 24 where the molecular oxygen in the second zone is removed by drawing a vacuum on the second zone.

Claim 28

A process for reacting a hydrocarbon gas with oxygen, the process comprising: (A) Feeding a first oxygen-containing gas into a first zone of a gas separation apparatus, the apparatus comprising first and second zones separated by a mixed metal oxide membrane, the membrane having a first surface open to the first zone, and a second surface open to the second zone, and an empirical formula of BiA.sub.x M.sub.y M'.sub.z O.sub.n where A is at least one of La, U, Th, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Lu, Y, Mg, Ca and Ba; M is at least one of Sc, Ti, Cr, Mn, Fe, Ni, Cu and Zn; M' is at least one of Co, Rh, Pd, Pt and Ru; x and y are individually a number between about 0.01 and about 10; z is a number of 0 to about 0.2; and n is a number that satisfies the valance requirements of the other elements present; the first zone having an equilibrium oxygen partial pressure greater than that of the second zone; (B) Contacting the first oxygen-containing gas in the first zone of the separation apparatus with the first surface of the membrane such that: (i) oxygen is extracted from the first oxygen-containing gas at the first surface of the membrane; and (ii) the extracted oxygen is transported across the membrane, in the form of oxide ions, to the second surface of the membrane; and (C) Contacting the extracted oxygen present on the second surface of the membrane with the hydrocarbon gas which is present in the second zone and is in contact with the second surface of the membrane such that the extracted oxygen and hydrocarbon gas react to form a second oxygen-containing gas.

Claim 29

A process for reacting a hydrocarbon gas with oxygen, the process comprising: (A) Feeding a first oxygen-containing gas into a first zone of a gas separation apparatus, the apparatus comprising first and second zones separated by a mixed metal oxide membrane, the membrane having a first surface open to the first zone, and a second surface open to the second zone, and an empirical formula of BiA.sub.x M.sub.y M'.sub.z O.sub.n where A is at least one of La, U, Th, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Lu, Y, Mg, Ca and Ba; M is at least one of Sc, Ti, Cr, Mn, Fe, Ni, Cu and Zn; M' is at least one of Co, Rh, Pd, Pt and Ru; x and y are individually a number between about 0.01 and about 10; z is a number of 0 to about 0.2; and n is a number that satisfies the valance requirements of the other elements present; the first zone having an equilibrium oxygen partial pressure greater than that of the second zone; (B) Contacting the first oxygen-containing gas in the first zone of the separation apparatus with the first surface of the membrane such that: (i) oxygen is extracted from the first oxygen-containing gas at the first surface of the membrane; and (ii) the extracted oxygen is transported across the membrane, in the form of oxide ions, to the second surface of the membrane; and (C) Contacting the extracted oxygen present on the second surface of the membrane with the hydrocarbon gas which is present in the second zone and is in contact with the second surface of the membrane such that the extracted oxygen and hydrocarbon gas react to form a second oxygen-containing gas.

Claim 30

The process of claim 27 where x is a number between about 0.2 and about 5, and small y is a number between about 0.2 and about 7.

Claim 31

The process of claim 27 where x is a number between about 0.5 and about 5, small y is a number between about 0.5 and about 3, and z is a number greater than 0.

Claim 32

The process of claim 28 or 29 where A is at least one of La, Ca, Y, Ba, Ce, U and Gd, M is at least one of Fe, Cu, Cr and Ni, and M' is at least one of Co, Rh, Pd and Ru.

Claim 33

The process of claim 28 or 29 where A is at least one of La, Ca, and Ba, M is at least one of Fe, Ni and Cr, and M' is at least one of Co, Ru and Pd.

Claim 34

The process of claim 30 where the first oxygen-containing gas comprises at least one of air, sulfur dioxide, and a nitrogen oxide.

Claim 35

The process of claim 30 where the first oxygen-containing gas comprises air.

Claim 36

The process of claim 32 where the hydrocarbon gas is at least one of ethane, ethylene, propane, propylene, butane, butenes, light naphtha, mixtures of paraffins, mixtures of paraffins and olefins, mixtures of paraffins, olefins and aromatics, and aromatics.

Claim 37

The process of claim 34 where the membrane is used in the absence of support.

Claim 38

The process of claim 34 where the temperature of each zone is between about 300° and about 900° C.

Claim 39

The process of claim 34 where the temperature of each zone is between about 400° and about 800° C.

Claim 40

The process of claim 37 where the second oxygen-containing gas is removed from the second zone by a sweep gas.

Claim 41

A process for separating oxygen from a first oxygen-containing gas, the process comprising: (A) Feeding the first oxygen-containing gas into a first zone of a gas separation apparatus, the apparatus comprising first and second zones separated by a mixed metal oxide membrane, the membrane having a first surface open to the first zone, a second surface open to the second zone, and an empirical formula of BiA.sub.x M.sub.y M'.sub.z O.sub.n where A is at least one of La, U, Th, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Lu, Y, Mg, Ca, Sr, and Ba; M is at least one of Sc, Ti, Cr, Mn, Fe, Ni, Cu and Zn; M' is at least one of Co, Rh, Pd, Pt and Ru; x and y are individually a number between about 0.01 and about 10; z is a number of greater than 0 to about 0.2; and n is a number that satisfies the valence requirements of the other elements present; the first zone having an equilibrium oxygen partial pressure greater than that of the second zone; (B) Contacting the first oxygen-containing gas in the first zone of the separation apparatus with the first surface of the membrane such that: (i) oxygen is extracted from the first oxygen-containing gas at the first surface of the membrane; and (ii) the extracted oxygen is transported across the membrane, in the form of oxide ions, to the second surface of the membrane; and (C) Reacting the extracted oxygen present on the second surface of the membrane with an oxygen-consuming substance that is present in the second zone and is in contact with the second surface of the membrane.

Claim 42

A process for separating oxygen from a first oxygen-containing gas, the process comprising: (A) Feeding the first oxygen-containing gas into a first zone of a gas separation apparatus, the apparatus comprising first and second zones separated by a mixed metal oxide membrane, the membrane having a first surface open to the first zone, a second surface open to the second zone, and an empirical formula of BiA.sub.x M.sub.y M'.sub.z O.sub.n where A is at least one of La, U, Th, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Lu, Y, Mg, Ca, Sr, and Ba; M is at least one of Sc, Ti, Cr, Mn, Fe, Ni, Cu and Zn; M' is at least one of Co, Rh, Pd, Pt and Ru; x and y are individually a number between about 0.01 and about 10; z is a number of greater than 0 to about 0.2; and n is a number that satisfies the valence requirements of the other elements present; the first zone having an equilibrium oxygen partial pressure greater than that of the second zone; (B) Contacting the first oxygen-containing gas in the first zone of the separation apparatus with the first surface of the membrane such that: (i) oxygen is extracted from the first oxygen-containing gas at the first surface of the membrane; and (ii) the extracted oxygen is transported across the membrane, in the form of oxide ions, to the second surface of the membrane; and (C) Reacting the extracted oxygen present on the second surface of the membrane with an oxygen-consuming substance that is present in the second zone and is in contact with the second surface of the membrane.

Claim 43

A process for reacting a hydrocarbon gas with oxygen, the process comprising: (A) Feeding a first oxygen-containing gas into a first zone of a gas separation apparatus, the apparatus comprising first and second zones separated by a mixed metal oxide membrane, the membrane having a first surface open to the first zone, a second surface open to the second zone, and an empirical formula of BiA.sub.x M.sub.y M'.sub.z O.sub.n where A is at least one of La, U, Th, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Lu, Y, Mg, Ca, Sr, and Ba; M is at least one of Sc, Ti, Cr, Mn, Fe, Ni, Cu and Zn; M' is at least one of Co, Rh, Pd, Pt and Ru; x and y are individually a number between about 0.01 and about 10; z is a number of greater than 0 to about 0.2; and n is a number that satisfies the valence requirements of the other elements present; the first zone having an equilibrium oxygen partial pressure greater than that of the second zone; (B) Contacting the first oxygen-containing gas in the first zone of the separation apparatus with the first surface of the membrane such that: (i) oxygen is extracted from the first oxygen-containing gas at the first surface of the membrane; and (ii) the extracted oxygen is transported across the membrane, in the form of oxide ions, to the second surface of the membrane; and (C) Contacting the extracted oxygen present on the second surface of the membrane with the hydrocarbon gas which is present in the second zone and is in contact with the second surface of the membrane such that the extracted oxygen and hydrocarbon gas react to form a second oxygen-containing gas.

Claim 44

A process for reacting a hydrocarbon gas with oxygen, the process comprising: (A) Feeding a first oxygen-containing gas into a first zone of a gas separation apparatus, the apparatus comprising first and second zones separated by a mixed metal oxide membrane, the membrane having a first surface open to the first zone, a second surface open to the second zone, and an empirical formula of BiA.sub.x M.sub.y M'.sub.z O.sub.n where A is at least one of La, U, Th, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Lu, Y, Mg, Ca, Sr, and Ba; M is at least one of Sc, Ti, Cr, Mn, Fe, Ni, Cu and Zn; M' is at least one of Co, Rh, Pd, Pt and Ru; x and y are individually a number between about 0.01 and about 10; z is a number of greater than 0 to about 0.2; and n is a number that satisfies the valence requirements of the other elements present; the first zone having an equilibrium oxygen partial pressure greater than that of the second zone; (B) Contacting the first oxygen-containing gas in the first zone of the separation apparatus with the first surface of the membrane such that: (i) oxygen is extracted from the first oxygen-containing gas at the first surface of the membrane; and (ii) the extracted oxygen is transported across the membrane, in the form of oxide ions, to the second surface of the membrane; and (C) Contacting the extracted oxygen present on the second surface of the membrane with the hydrocarbon gas which is present in the second zone and is in contact with the second surface of the membrane such that the extracted oxygen and hydrocarbon gas react to form a second oxygen-containing gas.