Preparation of palladium membrane on Pd/silicalite-1 zeolite particles modified macroporous alumina substrate for hydrogen separation

A palladium composite membrane was successfully fabricated by electroless plating on a macroporous alumina tube. Pd/silicalite-1 zeolite particles were employed to reduce the pore size of the alumina support and improve its surface roughness. Moreover, the Pd⁰ existed in the Sil-1 particle can avoid the time consuming sensitization and activation steps for palladium seeding. Scanning electron microscopy (SEM), energy dispersive X-ray spectroscopy (EDXS) and X-ray diffraction (XRD) analysis were conducted for analyzing the detailed microstructure of the palladium composite membrane. The hydrogen permeation performance of the resulting palladium membrane was investigated at temperatures of 623 K, 673 K, 723 K and 773 K. The hydrogen permeance of 1.95 × 10⁻⁶ mol m⁻² s⁻¹ Pa⁻¹ with an H₂/N₂ ideal selectivity of 1165 for the palladium membrane was obtained at 773 K. Furthermore, the resulting palladium membrane was stable for a long-term operation of 15 days at 673 K.     

Preparation of thin Pd membrane on porous stainless steel tubes modified by a two-step method

Thin Pd membranes for hydrogen filtration were deposited on modified porous stainless steel (PSS) tubes using an electroless plating technique. Alumina oxide (Al₂O₃) particles of two different sizes were subsequently used to modify the non-uniform pore distribution and the surface roughness of the PSS tubes. The principle of the modification was to use large Al₂O₃ particles (∼10 μm) to fill larger pores on the surface, and leave the smaller pores intact. Small Al₂O₃ particles (∼1 μm) were then used to further decrease the surface roughness. The detailed manufacturing steps of the Al₂O₃ modification were investigated and optimized to achieve a continuous dense Pd membrane with a minimum thickness of 4.4 μm on the modified PSS tubes. The highest hydrogen permeance of the membrane was 2.94 × 10⁻³ mol/m²-s-kPa^0.5 at 773 K, with a selectivity coefficient (H₂/He) of 1124 under a pressure difference of 800 kPa. In comparison, the thickness and hydrogen permeance of a dense Pd membrane on unmodified PSS tubes were 31.5 μm and 5.97 × 10⁻⁴ mol/m²-s-kPa^0.5, respectively, at 773 K under an 800 kPa pressure difference. The stability of the membranes at high temperatures was also investigated. The hydrogen permeation flux at 773 K was stable during a test period of 500 h. These results demonstrate that the two-step method modifies the surface of PSS tubes in a relatively simple way and results in thin, dense Pd membranes with high hydrogen permeance and good thermal stability.     

Electroless Pd membrane deposition on alumina modified porous Hastelloy substrate with EDTA-free bath

This study demonstrates palladium membranes can be electrolessly plated on aluminum oxide-modified porous Hastelloy with hydrazine using an EDTA-free bath. The plating bath temperature affected the membrane surface morphology, with the palladium grain size increasing with increasing temperature. A 7.5 μm thick membrane plating was obtained at room temperature. Helium leak testing confirmed that the membrane was free of defects. Hydrogen permeation test showed that the membrane had a hydrogen permeation flux of 3.3 × 10⁻¹ mol m⁻² s⁻¹ at a temperature of 823 K and at a pressure difference of 100 kPa. There was no measurable interdiffusion between the membrane film and the porous Hastalloy substrate at 823 K. This room temperature membrane plating method provides several advantages such as very high selectivity, stability, favorable energy efficiency and simplicity.     

Pd–Cu alloy membrane deposited on CeO2 modified porous nickel support for hydrogen separation

In this study, the hydrogen permeation behavior of a Pd₉₃–Cu₇ alloy membrane deposited on ceria-modified porous nickel support (PNS) was evaluated. PNS, which has an average pore size of 600 nm, was modified by alumina sol. Alumina sol was prepared using precursors that had a mean particle size of 300 nm. Alumina-modified PNS was further treated with ceria sol modification to produce a smoother surface morphology and narrow surface pores. A 7 μm thick Pd₉₃–Cu₇ alloy membrane was made on an alumina-modified PNS and a ceria-finished membrane was fabricated by magnetron sputtering followed by Cu-reflow at 700 °C for 2 h. SEM analysis showed that the membrane deposited on a ceria-finished PNS contained more clear grain boundaries than the membrane deposited on the alumina-modified PNS. The membrane was mounted in a stainless steel permeation cell with a gold-plated stainless steel O-ring. Permeation tests were then conducted using pure hydrogen and helium at temperatures ranging from 673 to 773 K and feed side pressures ranging from 100 to 400 kPa. These tests showed that the membrane had a hydrogen permeation flux of 2.8 × 10⁻¹ mol m⁻² s⁻¹ with H₂/He selectivity of >50,000 at a temperature of 773 K and pressure difference of 400 kPa.     

Copper deposition on Pd membranes by electroless plating

PdCu membranes were prepared by the electroless plating of Pd membranes prepared on ceramic tubular supports. Different PdCu membranes were prepared with Pd content between 45 and 77 wt% and a total metal layer between 0.5 and 1.9 μm thickness. The alloying step was performed in two ways to compare and establish the required alloying time for obtaining high permeance membranes. The alloying was analysed with EDX composition measurements, and full alloying was not required to obtain a stable hydrogen flux. Finally, permeance tests were performed at different pressures, including temperature cycles in hydrogen and nitrogen, to observe membrane stability. The hydrogen permeance values of the membranes were high, between 1.5 × 10⁻³ and 4.5 × 10⁻³ mol/(s Pa^0.5 m²) at 673 K. The membranes recorded stable permeance values even after thermal cycles in a hydrogen atmosphere. Metal layer thickness was calculated using both the weight difference method and SEM images. SEM images were also used to analyse the surface morphology of the membranes, which was generally fairly uniform and smooth.     

Influence of the type of siliceous material used as intermediate layer in the preparation of hydrogen selective palladium composite membranes over a porous stainless steel support

In this work, several composite membranes were prepared by Pd electroless plating over modified porous stainless steel tubes (PSS). The influence of different siliceous materials used as intermediate layers was analyzed in their hydrogen permeation properties. The addition of three intermediate siliceous layers over the external surface of PSS (amorphous silica, silicalite-1 and HMS) was employed to reduce both roughness and pore size of the commercial PSS supports. These modifications allow the deposition of a thinner and continuous layer of palladium by electroless plating deposition. The technique used to prepare these silica layers on the porous stainless steel tubes is based on a controlled dip-coating process starting from the precursor gel of each silica material. The composite membranes were characterized by SEM, AFM, XRD and FT-IR. Moreover they were tested in a gas permeation set-up to determine the hydrogen and nitrogen permeability and selectivity. Roughness and porosity of original PSS supports were reduced after the incorporation of all types of silica layers, mainly for silicalite-1. As a consequence, the palladium deposition by electroless plating was clearly influenced by the feature of the intermediate layer incorporated. A defect free thin palladium layer with a thickness of ca. 5 μm over the support modified with silicalite-1 was obtained, showing a permeance of 1.423·10⁻⁴ mol m⁻² s⁻¹ Pa^−0.5 and a complete ideal permselectivity of hydrogen.     

Hydrogen production from methane using vanadium-based catalytic membrane reactors

The application of vanadium-based membranes as the hydrogen separation membrane for a catalytic membrane reactor system was investigated for the direct production of hydrogen from methane. The methane conversion and hydrogen production rates of the catalytic membrane reactor system with Pd-coated 100 μm-thick vanadium-based membranes were comparable with the reactor using 50 μm-thick Pd–Ag alloy membrane at all temperatures examined. The methane conversion rates of the catalytic membrane reactor with the Pd-coated vanadium-based membranes were approximately 35% and 62% at 623 K and 773 K, respectively. The hydrogen production rates were around 660  μmol min⁻¹ at 623 K, and reached over 1710  μmol min⁻¹ at 773 K. The relationship between the methane conversion rates and hydrogen permeation fluxes of the catalytic membrane reactor confirmed that the removal of hydrogen from the reaction site enhances the methane decomposition reaction. Further, the vanadium based membrane exhibited good stability against Fe in a hydrogen containing atmosphere.     

Hydrogen permeation through a Pd/Ta composite membrane with a HfN intermediate layer

Dense hafnium nitride (HfN) layers were prepared between Pd protection films and a Ta substrate in a composite hydrogen separation membrane to prevent a reaction between the Pd and the substrate at high temperatures. No significant reduction in hydrogen permeation rate was observed for the membrane with 50-nm-thick HfN layers at 873 K through at least 35 h, whereas the specimen without HfN layers rapidly deteriorated within 5 h. Hydrogen permeability of the former specimen was 4 × 10⁻⁹ mol m⁻¹ s⁻¹ Pa^−0.5 at 873 K at steady state. This value was smaller than the initial permeability of Pd-covered Ta before deterioration by an order of magnitude. The measurements of pressure–composition isotherms by using a HfN powder specimen showed that the hydrogen solubility in HfN was sufficiently high and comparable with the solubility in Ta. Therefore, the low permeability observed with the HfN intermediate layers was ascribed to low hydrogen diffusivity in HfN.     

PdCu membrane integration and lifetime in the production of hydrogen from methane

PdCu membranes prepared by sequential electroless plating were integrated into a hydrogen production and purification process. Hydrogen was produced from methane through catalytic partial oxidation and wet catalytic partial oxidation with Ni-based catalysts. Membrane permeance was measured with thermal cycles in an inert and hydrogen atmosphere at 673 and 773 K. Permeability was 1.98·10⁻³ mol/(smPa^0.5) at 673 K and 2.62·10⁻³ mol/(smPa^0.5) at 773 K. The optimum sweep gas flow required in the membrane module when operating with hydrogen-containing mixtures was selected. Peak hydrogen recovery was obtained using 15–20% of the feed to the module as sweep gas flow. Membranes were then placed downstream of the hydrogen production reactor. The CO and H₂O percentages fed to the membrane module did not have a major impact on membrane behavior. Around 60–67% of the hydrogen fed to the membrane module was separated, regardless of its composition.     

High-flux H2 separation membranes from (Pd/Au)n nanolayers

A novel strategy for the preparation of supported PdAu alloy layers allows the facile and fast fabrication of highly permeable and selective H₂ separation membranes from refractory metals via electroless plating and low-temperature alloying. Homogenous alloying of multiple, separately deposited Pd and Au layers with thickness in the nm range required less than one week at 773 K under atmospheric H₂ as evidenced by X-ray diffraction and H₂ permeation measurements. The H₂ permeation rate JH₂ became stable within a day even, reaching 0.62 mol m⁻² s⁻¹ at 773 K and ΔPH₂ = 100 kPa. The corresponding N₂ leak rate remained constant during a 350 h experiment, resulting in an ideal H₂/N₂ selectivity of 1400 and demonstrating that such membranes tolerate extended operation at that temperature well.     

An improvement of the hydrogen permeability of C/Al2O3 membranes by palladium deposition into the pores

The development of compact hydrogen separator based on membrane technology is of key importance for hydrogen energy utilization, and the Pd-modified carbon membranes with enhanced hydrogen permeability were investigated in this work. The C/Al₂O₃ membranes were prepared by coating and carbonization of polyfurfuryl alcohol, then the palladium was introduced through impregnation–precipitation and colloid impregnation methods with a PdCl₂/HCl solution and a Pd(OH)₂ colloid as the palladium resources, and the reduction was carried out with a N₂H₄ solution. The resulting Pd/C/Al₂O₃ membranes were characterized by means of SEM, EDX, XRD, XPS and TEM, and their permeation performances were tested with H₂, CO₂, N₂ and CH₄ at 25 °C. Compared with the colloid impregnation method, the impregnation–precipitation is more effective in deposition of palladium clusters inside of the carbon layer, and this kind of Pd/C/Al₂O₃ membranes exhibits excellent hydrogen permeability and permselectivity. Best hydrogen permeance, 1.9 × 10⁻⁷ mol/m² s Pa, is observed at Pd/C = 0.1 wt/wt, and the corresponding H₂/N₂, H₂/CO₂ and H₂/CH₄ permselectivities are 275, 15 and 317, respectively.     

Preparation and performance of thin-layered PdAu/ceramic composite membranes

Preparation of 3–5 μm thick, hydrogen-selective PdAu layers via sequential electroless plating of Pd and Au onto ceramic microfiltration membranes was investigated employing a cyanide-free Au plating bath. The Au deposition rate was strongly dependent on bath temperature and alkalinity reaching an optimum at 333 K and pH 10. Homogenous alloying of the separate metal layers under atmospheric H₂ proved to be a protracted process and required approximately a week at 873 K for a PdAu layer as thin as 3 μm. After 300 h annealing at 823 K the 5 μm thick PdAu layer of a composite membrane still exhibited a Au gradient declining from 7.4 at.% at the top surface to 5.5 at.% at the support interface despite that the H₂ permeation rate had become stable. Nonetheless, the membrane exhibited a very high H₂ permeability of e.g. 1.3 × 10⁻⁸ mol m m⁻² s⁻¹ Pa^−0.5 at 673 K, but it decreased much faster with temperature below 573 K than above, likely due to a change from bulk H diffusion-controlled to H₂ adsorption or desorption-limited transport. The composite membrane withstood cycling between 523 and 723 K in H₂ well showing that differing thermal expansion of the joined metallic and ceramic materials stayed within the tolerance range up to 723 K.     

Fabrication of Pd/ceramic membranes for hydrogen separation based on low-cost macroporous ceramics with pencil coating

Increasing hydrogen energy utilization has greatly stimulated the development of the hydrogen-permeable palladium membrane, which is comprised of a thin layer of palladium or palladium alloy on a porous substrate. This work chose the low-cost macroporous Al₂O₃ as the substrate material, and the surface modification was carried out with a conventional 2B pencil, the lead of which is composed of graphite and clay. Based on the modified substrate, a highly permeable and selective Pd/pencil/Al₂O₃ composite membrane was successfully fabricated via electroless plating. The membrane was characterized by SEM (scanning electron microscopy), field-emission SEM and metallographic microscopy. The hydrogen flux and H₂/N₂ selectivity of the membrane (with a palladium thickness of 5 μm) under 1 bar at 723 K were 25 m³/(m² h) and 3700, respectively; the membrane was found to be stable during a time-on-stream of 330 h at 723 K.     

Improved hydrogen permeation through thin Pd/Al2O3 composite membranes with graphene oxide as intermediate layer

Here we proposed the decreasing in the roughness of asymmetric alumina (Al₂O₃) hollow fibers by the deposition of a thin graphene oxide (GO) layer. GO coated substrates were then used for palladium (Pd) depositions and the composite membranes were evaluated for hydrogen permeation and hydrogen/nitrogen selectivity. Dip coating of alumina substrates for 45, 75 and 120 s under vacuum reduced the surface mean roughness from 112.6 to 94.0, 87.1 and 62.9 nm, respectively. However, the thicker GO layer (deposited for 120 s) caused membrane peel off from the substrate after Pd deposition. A single Pd layer was properly deposited on the GO coated substrates for 45 s with superior hydrogen permeance of 24 × 10⁻⁷ mol s⁻¹m⁻² Pa⁻¹ at 450 °C and infinite hydrogen/nitrogen selectivity. Activation energy for hydrogen permeation through the Al₂O₃/GO/Pd composite membrane was of 43 kJ mol⁻¹, evidencing predominance of surface rate-limiting mechanisms in hydrogen transport through the submicron-thick Pd membrane.     

Evaluations of hydrogen permeation on TiN-5 wt.%Ni membrane by spark plasma sintering

The TiN-5 wt.%Ni membrane was researched for gasification of coal technique, separating hydrogen from fossil fuel. In general, Pd and Pd-based alloy membranes of separating hydrogen were reported to have the good property of hydrogen selectivity at high temperature, but they has some problems such as hydrogen embrittlement and high material costs. Therefore, materials with good properties of hydrogen selectivity are needed instead of Pd. In this research, we fabricated membranes for hydrogen permeation that are highly resistant to acids, chemically steady, and composed of the economical substance, TiN. Our laboratory investigated hydrogen selectivity. TiN powder was milled for 30, 60, and 240 min by a vibration mill, respectively. Afterwards, the samples underwent operate spark plasma sintering and was characterized by XRD, BET, and SEM. Also, hydrogen selectivity was measured by Sievert’s type hydrogen permeation membrane equipment. In this report, the hydrogen permeability of the TiN-5 wt.%Ni membrane was measured to be 7.8 × 10⁻⁸, 1.7 × 10⁻⁷, and 1.4 × 10⁻⁷ mol/m·s·Pa^1/2 at 473, 573, and 673K under 0.2 MPa H₂ atmosphere, respectively.     

Ultra-compact microstructured methane steam reformer with integrated Palladium membrane for on-site production of pure hydrogen: Experimental demonstration

A novel metal-based modular microstructured reactor with integrated Pd membrane for hydrogen production by methane steam reforming is presented. Thin Pd foils with a thickness of 12.5 μm were leak-tight integrated with laser welding between microstructured plates. The laser-welded membrane modules showed ideal H₂/N₂ permselectivities between 16,000 and 1000 at 773 K and 6 bar retentate pressure. An additional metal microsieve support coated with an YSZ diffusion barrier layer (DBL) facilitated the operation at temperatures up to 873 K and pressures up to 20 bar pressure difference. The membrane permeability in this configuration is expressed with Q = 1.58E-07*exp(−1460.2/T) mol/(msPa^0.5).     

Rhodium(0), Ruthenium(0) and Palladium(0) nanoparticles supported on carbon-coated iron: Magnetically isolable and reusable catalysts for hydrolytic dehydrogenation of ammonia borane

We report the synthesis of magnetically isolable ruthenium(0), rhodium(0), and palladium(0) nanoparticles, supported on carbon-coated magnetic iron particles, and their employment as catalysts in hydrolysis of ammonia borane. Carbon-coated iron (C–Fe) particles are obtained by co-processing of iron powders with methane in a radio frequency thermal plasma reactor. The impregnation of ruthenium(III), rhodium(III) and palladium(II) ions on the carbon-coated iron particles followed by aqueous solution of sodium borohydride leads to the formation of respective metal(0) nanoparticles supported on carbon-coated iron, M⁰/C–Fe NP (M = Ru, Rh, and Pd) at room temperature. M⁰/C–Fe NPs are characterized using the ICP-OES, XPS, TEM, and EDX techniques and tested as catalysts for hydrolysis of ammonia borane at 298 K. The results reveal that Rh⁰/C–Fe, Ru⁰/C–Fe, Pd⁰/C–Fe catalysts provide turnover frequency of 83, 93, and 29 min^?1, respectively, in this industrially important reaction. More importantly, these magnetically separable metal(0) nanoparticles show very high reusability with no noticeable activity loss in subsequent runs of hydrolysis evolving 3.0 equivalent H₂ per mole of ammonia borane.     

Hydrogen permeation measurements of Pd and Pd-Cu membranes using dynamic pressure difference method

Hydrogen permeation across membranes is measured using a dynamic pressure difference method. In the method, a transient system for continuously monitoring hydrogen flux of a membrane is conducted. Three different membranes, consisting of two pure palladium (Pd) membranes with different thicknesses and one palladium-copper (Pd-Cu) membrane supported by porous stainless steel (PSS) tubes, are taken into account. Three different operating temperatures of 320, 350 and 380 °C as well as two different initial pressure differences of 5 and 10 atm are considered to evaluate the effects of the operating parameters upon the hydrogen permeation. The results suggest that a threshold of pressure difference is always exhibited at the end of the permeation process, regardless of which membrane is tested. The hydrogen permeation rate can be predicted well for the pressure exponent in the range of 0.1-1.0; however, the optimal pressure exponent is located between 0.5 and 0.8. The theoretical analysis indicates that the characteristic time of hydrogen permeation in the present system ranges from 245 to 460 s and the entire permeation period is longer than the characteristic time by an order of magnitude. In regard to the effect of membrane temperature on the permeation, the activation energies of the three membranes range from 11 to 18 kJ mol⁻¹.     

Palladium composite membrane fabricated on rough porous alumina tube without intermediate layer for hydrogen separation

A thin palladium composite membrane without any modified layer was successfully obtained on a rough porous alumina substrate. Prior to the fabrication of palladium membrane, a poly(vinyl) alcohol (PVA) layer was first coated onto the porous substrate by dip-coating technique to improve its surface roughness and pore size. After deposition of palladium membrane on the PVA modified substrate, the polymer layer can be completely removed from the composite membrane by heat treatment. The microstructure of the palladium composite membrane was characterized in detail using SEM, EDXS and XRD analysis. Permeation measurements were carried out using H₂ and N₂ at temperatures of 623 K, 673 K, 723 K and 773 K. The results indicated that the hydrogen permeation flux of 0.238 mol m^?2 s^?1 with H₂ separation factor α(H₂/N₂) of 956 for the as-prepared palladium membrane was obtained at 773 K and 100 kPa. Furthermore, the good membrane stability was proven during the total operation time of 160 h at the temperature range of 623 K–773 K and gas exchange cycles of 30 between hydrogen and nitrogen at 723 K.     

Characterization of Pd–Cu membranes fabricated by surfactant induced electroless plating (SIEP) for hydrogen separation

Pd–Cu composite membranes on microporous stainless steel (MPSS) substrate were fabricated using surfactant induced electroless plating (SIEP). In the SIEP method, dodecyl trimethyl ammonium bromide (DTAB), a cationic surfactant, was used in Pd- and Cu-baths for the sequential deposition of metals on MPSS substrates. The SIEP Pd–Cu membrane performance was compared with membranes fabricated by conventional electroless plating (CEP). The pre- and post-annealing characterizations of these membranes were carried out by SEM, XRD, EDX and AFM studies. The SEM images showed a significant improvement of the membrane surface morphology, in terms of metal grain structures and grain agglomeration compared to the CEP membranes. The SEM images and helium gas-tightness studies indicated that dense and thinner films of Pd–Cu can be produced with shorter deposition time using SIEP method. From XRD, cross-sectional SEM and EDS studies, alloying of Pd–Cu was confirmed at an annealing temperature of 773 K under hydrogen environment. These membranes were also studied for H₂ perm-selectivity as a function of temperature and feed pressure. SIEP membranes had significantly higher H₂ perm-selectivity compared to CEP membranes. Under thermal cycling (573 K – 873 K – 573 K), the SIEP Pd–Cu membrane was stable and retained hydrogen permeation characteristics for over three months of operation.