Design and modeling of a plasma reactor for the production of O2 from the conversion of CO2

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Driven by the need to value CO2 as a resource, this work designs a compact Dielectric Barrier Discharge (DBD) plasma reactor integrating non-thermal plasma CO2 dissociation with Mixed Ionic-Electronic Conducting (MIEC) membranes for selective oxygen separation and CO-based fuel production, targeting Mars in-situ resource utilization (ISRU), and terrestrial O2 generation.

A multiphysics framework using Gmsh, ElmerGRID, ElmerFEM, and ParaView guided reactor optimization with axisymmetrical 2D and 3D models. For future integration in the reactor, perovskite MIEC membranes of Ba0.5Sr0.5Co0.8Fe0.2O3−δ (BSCF) and La0.6Sr0.4Co0.2Fe0.8O3−δ (LSCF) were synthesized via uniaxial pressing and silk-printing. A comparative analysis using X-ray diffraction (XRD), scanning electron microscopy (SEM), and differential thermal analysis (DTA) evaluated the fabrication routes. The silkprinting method yielded LSCF membranes with superior microstructural homogeneity and mechanical integrity, while XRD confirmed both methods produce the required perovskite structure.

DTA established the ceramic’s thermal behavior, revealing a BSCF melting point near 1250◦C. Simulation of the reactor shows that the necessary thermal conditions of approximately 730◦C can be obtained with a 10 W heating power and 10 W plasma power. The model also includes stress analysis under operating conditions. Crucially, the combined heating strategy maintains the membrane’s activation temperature, while the computed flow fields ensure sufficient gas-plasma contact for conversion.

These results provide a critical blueprint for a functional prototype, de-risking the final design by ensuring compatibility with the MIEC membrane environment.