Oxygen
is a critical industrial gas whose global market is projected
to reach $48 billion/year within this decade. However, oxygen production
is highly energy-intensive because of the limited efficiency of the
commercial cryogenic air separation technology. The present study
systematically investigated a chemical looping air separation (CLAS)
approach as an alternative to cryogenic distillation. In particular,
a Sr0.8Ca0.2Fe0.4Co0.6O3−δ (SCFC) oxygen sorbent was used as the
basis for both experimental and simulation studies. To demonstrate
the sorbent robustness, experimental studies were carried out over
10,000 redox cycles in a bench-scale testbed. Excellent sorbent stability
and >90% oxygen purity were achieved using steam as the purge gas.
Oxygen purity can be further increased to >95% by optimizing the
operating
conditions and pressure swing absorption cycle structure. Based on
the experimental results, a CLAS system design and a process model
were established. The process model estimates a base case CLAS energy
consumption of 0.66 MJ/kg O2. This represents a 15% decrease
compared to cryogenic air separation (0.78 MJ/kg O2). It
is noted that most of the thermal energy consumed by CLAS is at relatively
low temperatures (∼120 °C). When accounting for the quality
of this low-grade heat, an energy consumption as low as 0.40 MJ/kg
O2 can be anticipated for a practical system. Sensitivity
analysis was also performed on the various CLAS operational and design
parameters such as reactor sizes, pressure drop, thermodynamic driving
forces, oxygen uptake and release rates, heat loss, and the energy
consumption for steam generation. It was determined that CLAS has
excellent potential to be an efficient oxygen production technology.
This study also highlights the importance of developing advanced sorbents
with suitable redox thermodynamics and fast redox kinetics for improved
efficiency and smaller reactor sizes.