Ceramic Oxygen Purification Stack Assembly for Thermal Expansion Sealing
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Solution Overview
Problem
Traditional methods for purifying oxygen gas are energy and resource-intensive, and existing on-site oxygen generation technologies are costly and inefficient, particularly for producing high-purity oxygen, posing challenges for industries and medical facilities.
Innovation Solution
A ceramic-based electrochemical stack system that includes a terminal plumbing assembly to manage thermal expansion mismatches, enabling efficient oxygen concentration and pressurization with reduced energy consumption, producing high-purity oxygen gas on-demand.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional oxygen purification methods (cryogenic air separation, pressure swing adsorption) are used, then high-purity oxygen can be produced, but energy consumption and operational costs increase significantly
Solution Approach 1:
The patent changes the operating parameters from extreme conditions (cryogenic temperatures of -300°F or pressure swing adsorption high pressures) to moderate temperatures (200-1000°C) using electrochemical membranes. This parameter change enables high-purity oxygen production while dramatically reducing energy consumption compared to traditional methods.
Solution Approach 2:
The patent replaces mechanical/physical separation systems (cryogenic distillation columns, pressure swing adsorption vessels with zeolites) with an electrochemical membrane system that uses electrical potential to drive oxygen ion transport through the ceramic membrane, achieving purification with lower energy input.
2Reliability
If on-site oxygen generation systems are implemented, then oxygen supply reliability improves, but device complexity and initial cost increase
Solution Approach 1:
The patent divides the oxygen generation system into modular electrochemical stack units, each comprising multiple ceramic membrane cells. This segmentation allows for scalable deployment where facilities can install only the number of modules needed, reducing initial complexity while maintaining reliability through redundancy.
Solution Approach 2:
The patent introduces a ceramic electrochemical membrane as an intermediary component that performs the oxygen separation function in a single step. This eliminates the need for complex multi-stage purification systems, cryogenic equipment, or large pressure vessels, thereby reducing overall system complexity while ensuring reliable oxygen production.
3Quantity of substance
If cryogenic air separation is used for oxygen production, then large volumes of oxygen can be produced, but infrastructure requirements and transportation needs increase
Solution Approach 1:
The patent transitions from centralized bulk oxygen production (cryogenic plants producing large volumes for distribution) to distributed on-site generation using electrochemical stacks. This dimensional shift from centralization to distribution eliminates the need for cryogenic storage tanks, insulated transportation vessels, and complex infrastructure while meeting oxygen demands directly at the point of use.
4Ease of operation
If pressure swing adsorption is used for oxygen generation, then on-site production is enabled, but oxygen purity and efficiency decrease for high-purity applications
Solution Approach 1:
The patent employs composite ceramic membranes with specific crystalline structures (such as gadolinium-doped ceria) that combine high oxygen ion conductivity with selective permeability. This composite material approach enables the membrane to achieve both on-site generation capability and high oxygen purity (95-99.5%) simultaneously, overcoming the limitations of pressure swing adsorption.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system achieves high-purity oxygen gas output with reduced energy and cost, eliminating the need for oxygen cylinders and cryogenic containers, and is suitable for on-site generation in various industries and medical applications.
Implementation Method 1
The electrochemical stack extracts oxygen from an input gas, outputs purified oxygen gas, and adds heat to the input gas because the ion transport process produces waste heat.
Implementation Method 2
The input gas is drawn into a heat exchanger and then heated with a heater prior to being processed through a stack assembly
Implementation Method 3
The input gas is drawn into a heat exchanger and then heated with a heater prior to being processed through a stack assembly
Data Source
AI summary
Systems for oxygen concentration and pressurization. An assembly includes an electrochemical stack comprising: a plurality of wafers, wherein the plurality of wafers comprises a first ceramic wafer and a second ceramic wafer; a ceramic spacer disposed in between the first ceramic wafer and the second ceramic wafer; and an interconnect disposed in between the first ceramic wafer and the second ceramic wafer that facilitates electrical communication between the first ceramic wafer and the second ceramic wafer. The assembly includes a metal tube for porting the purified oxygen gas output by the electrochemical stack. The assembly includes a terminal plumbing assembly that couples the electrochemical stack to the metal tube, wherein the terminal plumbing assembly comprises a ceramic adapter, a metal adapter, and an adapter skirt, and wherein the adapter skirt extends outward relative to a sidewall of the metal adapter.