Staged Oxygen Separation Elements with Ceramic-to-Metal Junction
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Solution Overview
Problem
Existing gas purification methods using electrically driven oxygen ion transport elements are inefficient due to separate module heating costs and incomplete oxygen separation in stages with low oxygen concentration, leading to overpowered downstream elements and reduced separation efficiency.
Innovation Solution
A staged purification method inducing turbulent flow in secondary oxygen ion transport elements and using a ceramic-to-metal junction for efficient heating and connection, allowing for more effective oxygen separation and reduced power consumption by heating all elements simultaneously.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If separate module heating is used for each oxygen separation element, then individual temperature control is achieved, but power consumption and operational costs increase significantly
Solution Approach 1:
Multiple oxygen separation elements are electrically connected in parallel and heated by a common power source rather than individual heating for each element. This merging of heating functions reduces total power consumption while maintaining operational temperature across all elements.
Solution Approach 2:
A single power source serves multiple oxygen separation elements simultaneously, performing the heating function for all elements at once. This universal heating approach eliminates the need for separate heating systems for each element, reducing overall energy consumption.
2Reliability
If downstream oxygen separation elements are overpowered to handle low oxygen concentration, then complete oxygen removal is achieved, but the elements are potentially damaged and separation efficiency decreases
Solution Approach 1:
The oxygen separation process is divided into multiple stages with each stage handling a specific oxygen concentration range. Upstream elements handle high oxygen concentration while downstream elements handle progressively lower concentrations, preventing any single element from being overpowered and ensuring complete oxygen removal through the staged approach.
Solution Approach 2:
Different oxygen separation elements are positioned in specific locations within the system to handle different oxygen concentrations. Upstream elements are designed for high concentration separation while downstream elements are optimized for low concentration removal, matching each element's capabilities to its local operating conditions.
3Ease of manufacture
If each process module is a separately enclosed structure, then modular assembly is achieved, but heating efficiency decreases and power consumption increases
Solution Approach 1:
Multiple oxygen separation elements are electrically connected in parallel and heated by a common power source rather than individual heating for each element. This merging of heating functions reduces total power consumption while maintaining operational temperature across all elements.
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 method achieves more efficient oxygen separation with reduced power consumption and cost-effective fabrication, ensuring complete removal of oxygen from gas streams by maintaining operational temperatures and optimizing flow conditions.
Implementation Method 1
The electrolyte layer is formed of an ionic conductor that is capable of conducting oxygen ions when subjected to an elevated temperature and an electrical potential is applied to the electrode layers
Implementation Method 2
the oxygen ions will ionize on one surface of the electrolyte layer and under the impetus of an electrical potential, will be transported through the electrolyte layer to the opposite side
Implementation Method 3
a ceramic-to-metal junction for efficient heating and connection, allowing for more effective oxygen separation and reduced power consumption by heating all elements simultaneously
Implementation Method 4
A secondary separation zone is connected to the outlet manifold. The secondary separation zone comprises a secondary oxygen separation element of tubular form connected to the primary separation zone to separate a secondary of the oxygen from the partly purified gas stream
Data Source
AI summary
Purification method and apparatus for purifying a gas stream by oxygen removal. The apparatus includes primary and secondary oxygen separation zones and tubular electrically driven oxygen separation elements. There are more elements in the primary zone than the secondary zone so that low concentrations of oxygen can be obtained in a purified stream and turbulent flow conditions can also be obtained that will permit purification to very low levels. In addition, a junction is provided to connect the tubular separation elements to metallic elements such as manifolds.