Dual function composite oxygen transport membrane

Abstract

A dual function composite oxygen transport membrane having a layered structure of mixed conducting oxygen transport materials on a first side of a porous substrate and a reforming catalyst layer on an opposing second side of the porous substrate. The layered structure of the mixed conducting oxygen transport materials contains an intermediate porous layer of mixed conducting oxygen transport materials formed on the porous substrate with a dense impervious layer of mixed conducting oxygen transport materials over the intermediate porous layer, and an optional surface exchange layer of mixed conducting oxygen transport materials over the dense impervious layer. The layered structure and the reforming catalyst layer are formed in separate steps.

1 - 10 . (canceled) 
     
     
         11 . A method of forming a dual function composite oxygen transport membrane, said method comprising: providing a porous substrate having a first side and an opposing second side; forming a layered structure of mixed conducting materials in a sintered state on the first side of the porous substrate; coating a catalyst layer on the opposing second side of the porous substrate for catalyzing endothermic reactions. 
     
     
         12 . The method of  claim 11  wherein the layered structure of mixed conducting materials comprises an intermediate porous layer, a dense layer, and an optional surface exchange layer, and the forming of the dense layer and the forming of the catalyst layer is carried out in separate steps. 
     
     
         13 . A method of forming a dual function composite oxygen transport membrane, said method comprising: providing a porous substrate having a first side and an opposing second side; forming an intermediate porous layer on the first side of the porous substrate; forming a dense layer over the intermediate porous layer; forming a surface exchange layer over the dense layer; and forming a catalyst layer on the opposing second side of the porous substrate. 
     
     
         14 . The method of  claim 13  wherein the forming of the catalyst layer is carried out after the forming of the surface exchange layer. 
     
     
         15 . The method of  claim 13  wherein a catalyst layer coating step in the forming of the catalyst layer is carried out prior to a high temperature sintering step in the forming of the surface exchange layer. 
     
     
         16 . The method of  claim 13  wherein a catalyst layer coating step in the forming of the catalyst layer is carried out prior to a coating step in the forming of the surface exchange layer. 
     
     
         17 . The method of  claim 13  wherein a catalyst layer coating step in the forming of the catalyst layer is a wash-coating technique.