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.     

On alloying and low-temperature stability of thin,supported PdAg membranes

Electroless plating is the technically most facile and most frequently studied method for preparation of PdAg/ceramic composite membranes. Limited high-temperature stability of such membranes requires alloying of sequentially deposited Pd and Ag layers far below their melting points, however. Here it is demonstrated that 600–800 h are needed for forming 2–4 μm thick, homogeneous alloy layers from Pd–Ag bilayers at 823 K under atmospheric H₂ pressure. This is also the time scale on which the activation energy for H₂ permeation becomes stable so that this characteristic can be employed for non-destructive, in-process monitoring of the alloying progress. High-temperature H₂ permeation rates are shown to be less well suited for this purpose because they are not sufficiently sensitive to the homogeneity of PdAg membranes. The activation energies for the well-alloyed membranes indicate that diffusion through the bulk of the PdAg layer limits H₂ permeation through these composite membranes. It is further shown that a fully alloyed Pd₇₅Ag₂₅ membrane tolerates temperature cycling under H₂ well down to 373 K while H₂/N₂ exchanges at that temperature trigger a rapid growth of the N₂ leak rate of that membrane. The defect formation is attributed to mechanical stress caused by the substantial expansion and shrinking of the alloy lattice during hydriding and dehydriding at low temperatures.     

Hydrogen permeation in asymmetric La28 − xW4 + xO54 + 3x/2 membranes

Asymmetric supported La_28 − xW_4 + xO_54 + 3x/2 (La/W ≈ 5.6) membranes were investigated for their hydrogen permeation properties as a function of temperature and feed gas conditions. Dense membranes of thickness 25–30 μm supported on substrates with 25 and 40 vol.% porosity were compared. Above 850 °C under dry conditions, the hydrogen permeation rate was approximately constant as a function of temperature due to low concentration of protons in the material at high temperatures. Under humid conditions and above 960 °C enhanced permeation rates were observed. A hydrogen permeation as high as 0.14 NmL min⁻¹ cm⁻² was recorded at 1000 °C with 10 vol.% H₂ (2.5 vol.% H₂O) as feed gas.     

Hydrogen permeation through a Pd-based membrane and RWGS conversion in H2/CO2, H2/N2/CO2 and H2/H2O/CO2 mixtures

This study investigated the effect of gases such as CO₂, N₂, H₂O on hydrogen permeation through a Pd-based membrane −0.012 m² – in a bench-scale reactor. Different mixtures were chosen of H₂/CO₂, H₂/N₂/CO₂ and H₂/H₂O/CO₂ at temperatures of 593–723 K and a hydrogen partial pressure of 150 kPa. Operating conditions were determined to minimize H₂ loss due to the reverse water gas shift (RWGS) reaction. It was found that the feed flow rate had an important effect on hydrogen recovery (HR). Furthermore, an identification of the inhibition factors to permeability was determined. Additionally, under the selected conditions, the maximum hydrogen permeation was determined in pure H₂ and the H₂/CO₂ mixtures. The best operating conditions to separate hydrogen from the mixtures were identified.     

Novel non-alloy Ru/Pd composite membrane fabricated by electroless plating for hydrogen separation

This study presents a new non-alloy Ru/Pd composite membrane fabricated by electroless plating for hydrogen separation. It shows that palladium and ruthenium can be deposited on an aluminum-oxide-modified porous Hastalloy by using our new EDTA-free plating bath at room temperature and 358 K, respectively. A 6.8 μm thick non-alloy Ru/Pd membrane film could be plated and helium leak test confirmed that the membrane was free of defects. Hydrogen permeation test showed that the membrane had a hydrogen permeation flux of 4.5 × 10⁻¹ mol m⁻² s⁻¹ at a temperature of 773 K and a pressure difference of 100 kPa. The hydrogen permeability normalized value with thickness of the membrane was 1.4 times higher than our pure Pd membrane having similar structure. The EDX profiles of the front and back side membrane, cross-sectional EDX line scanning and XRD profile show that there was no alloying progress between the palladium and ruthenium layer after hydrogen permeation test at 773 K.     

High temperature H2/CO2 separation using cobalt oxide silica membranes

In this work high quality cobalt oxide silica membranes were synthesized on alumina supports using a sol–gel, dip coating method. The membranes were subsequently connected into a steel module using a graphite based proprietary sealing method. The sealed membranes were tested for single gas permeance of He, H₂, N₂ and CO₂ at temperatures up to 600 °C and feed pressures up to 600 kPa. Pressure tests confirmed that the sealing system was effective as no gas leaks were observed during testing. A H₂ permeance of 1.9 × 10⁻⁷ mol m⁻² s⁻¹ Pa⁻¹ was measured in conjunction with a H₂/CO₂ permselectivity of more than 1500, suggesting that the membranes had a very narrow pore size distribution and an average pore diameter of approximately 3 Å. The high temperature testing demonstrated that the incorporation of cobalt oxide into the silica matrix produced a structure with a higher thermal stability, able to resist thermally induced densification up to at least 600 °C. Furthermore, the membranes were tested for H₂/CO₂ binary feed mixtures between 400 and 600 °C. At these conditions, the reverse of the water gas shift reaction occurred, inadvertently generating CO and water which increased as a function of CO₂ feed concentration. The purity of H₂ in the permeate stream significantly decreased for CO₂ feed concentrations in excess of 50 vol%. However, the gas mixtures (H₂, CO₂, CO and water) had a more profound effect on the H₂ permeate flow rates which significantly decreased, almost exponentially as the CO₂ feed concentration increased.     

The property of hydrogen separation from CO2 mixture using Pd-based membranes for carbon capture and storage (CCS)

This study investigates the module configuration for upscaling CO₂ capture capacity to a bench-scale in hydrogen selective Pd-based composite membranes. In order to confirm effective upscaling, four plate-type membranes of two inch diameter were stacked in a newly designed plate-and-frame type module, reaching a total membrane surface area of 6.64 × 10⁻³ m² (66.4 cm²). A pure gas test carried out using H₂ and He confirmed that there were no effects of module configuration in gas permeation behavior, indicating that the upscale of the separation capacity by numbering-up of membranes using our module design was successful. The CO₂ enrichment test was conducted using a 40%CO₂ + 60%H₂ mixture (i.e. a similar composition for the coal gasifier after both the shift reaction and H₂O removal), under high feed pressure and flow rate, i.e. 600–2100 kPa and 0.48–0.72 N m³ h⁻¹. The mixture gas test confirmed that the bench-scale membrane module could enrich 40% of the CO₂ at a feed flow rate of 0.48 N m³ h⁻¹ up to 93% with a hydrogen recovery ratio of >90% at 673 K and a total feed pressure of 2100 kPa, i.e. ∼4 times CO₂ enrichment capacity of one membrane.     

Bench-scale WGS membrane reactor for CO2 capture with co-production of H2

This study investigated the water-gas shift reaction in a bench-scale membrane reactor (M-WGS), where three supported Pd membranes of 44 cm in length and ca. 6 μm in thickness were used, reaching a total membrane surface area of 580.6 cm². The WGS reaction was studied with the syngas mixture: 4.0% CO, 19.2% CO₂, 15.4% H₂O, 1.2% CH₄ and 60.1% H₂, under high temperature/pressure conditions: T = 673 K, p_feed = 20–35 bar(a), p_perm = 15 bar(a), mimicking CO₂ capture with co-production of H₂ in a natural gas fired power plant. High reaction pressure and high permeation of Pd membranes allowed for near complete CO conversion and H₂ recovery. Both the membranes and the membrane reactor demonstrated a long-term stability under the investigated conditions, indicating the potential of M-WGS to substitute conventional systems.     

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.     

High catalytic kinetic performance of amorphous CoPt NPs induced on CeOx for H2 generation from hydrous hydrazine

CeO_x-induced amorphization of CoPt nanoparticles (NPs) is achieved by a facile co-reduction method using sodium borohydride (NaBH₄) as the reducing agent at room temperature (298 K) under ambient atmosphere. The investigation results indicate that CeO_x plays a critical role in transferring the crystalline CoPt nanoalloy into the amorphous one. To our surprise, the resultant Co_0.65Pt_0.30(CeO_x)_0.05 NPs exhibit high catalytic kinetic performance with 72.1% hydrogen (H₂) selectivity for the H₂ generation from hydrous hydrazine (N₂H₄) within only a few minute at 298 K. Although complete conversion is not achieved, but the initial turnover frequency value of 194.8 h⁻¹ for the present amorphous catalyst is much higher than that of crystalline one. Moreover, such a highly rapid catalyst may greatly encourage the practical application of hydrous N₂H₄ as a hydrogen storage material.     

Hydrogen permeation behavior of Nb30Ti35Ni35−xCox (x = 0…35) alloys containing high fractions of eutectic

The hydrogen permeability of cast Nb₃₀Ti₃₅Ni_35−xCo_x (x = 0…35) alloys is found to increase with the Co content, induced by the tailored microstructures containing high fractions of eutectic and less primary phase. Among the cast alloys, Nb₃₀Ti₃₅Co₃₅ consisting entirely of eutectic exhibits the highest permeability, particularly 2.65 × 10⁻⁸ mol H₂ m⁻¹ s⁻¹ Pa^−0.5 at 673 K. This permeability is further increased to 3.58 × 10⁻⁸ mol H₂ m⁻¹ s⁻¹ Pa^−0.5 by aligning eutectic grains perpendicularly to the membrane surface using directional solidification. The high permeability is attributed to the high hydrogen solubility and diffusivity in alloys. Our work demonstrates that hydrogen permeable alloys containing high fractions of eutectic may exhibit high permeability by adequately optimizing morphology, volume fraction and alignment of the bcc-Nb phase in the eutectic as the pathways for hydrogen permeation.     

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.     

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.     

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.     

Electrochemical synthesis of ammonia from N2 and H2O based on (Li,Na,K)2CO3–Ce0.8Gd0.18Ca0.02O2−δ composite electrolyte and CoFe2O4 cathode

Electrochemical synthesis of ammonia from water vapour and nitrogen was investigated using an electrolytic cell based on CoFe₂O₄–Ce0_.8Gd_0.18Ca_0.02O_2−δ (CFO-CGDC), CGDC-ternary carbonate composite and Sm_0.5Sr_0.5CoO_3−δ–Ce_0.8Gd_0.18Ca_0.02O_2−δ (SSCo-CGDC) as cathode, electrolyte and anode respectively. CoFe₂O₄, CGDC and SCCo were prepared via a combined EDTA-citrate complexing sol–gel and characterised by X-ray diffraction (XRD). The AC ionic conductivities of the CGDC-carbonate composite were investigated under three different atmospheres (air, dry O₂ and wet 5% H₂–Ar). A tri-layer electrolytic cell was fabricated by a cost-effective one-step dry-pressing and co-firing process. Ammonia was successfully synthesised from water vapour and nitrogen under atmospheric pressure and the maximum rate of ammonia production was found to be 6.5 × 10⁻¹¹ mol s⁻¹ cm⁻² at 400 °C and 1.6 V which is two orders of magnitude higher than that of previous report when ammonia was synthesised from N₂ and H₂O at 650 °C.     

A mixed electronic and protonic conducting hydrogen separation membrane with asymmetric structure

In this work, highly doped ceria with lanthanum, La_0.5Ce_0.5O_2−δ (LDC), are developed as hydrogen separation membrane material. LDC presents a mixed electronic and protonic conductivity in reducing atmosphere and good stability in moist CO₂ environment. LDC separation membranes with asymmetrical structure are fabricated by a cost-saving co-pressing method, using NiO + LDC + corn starch mixture as substrate and LDC as top membrane layer. Hydrogen permeation properties are systemically studied, including the influence of operating temperature, hydrogen partial pressure in feed stream and water vapor in both sides of the membrane on hydrogen permeating fluxes. Hydrogen permeability increases as the increasing of temperature and hydrogen partial pressure in feed gas. Using 20% H₂/N₂ (with 3% of H₂O) as feed gas and dry high purity argon as sweep gas, an acceptable flux of 2.6 × 10⁻⁸ mol cm⁻² s⁻¹ is achieved at 900 °C. The existing of water in both sides of membrane has significant effect on hydrogen permeation and the corresponding reasons are analyzed and discussed.     

Preparation of a novel bimodal catalytic membrane reactor and its application to ammonia decomposition for COx-free hydrogen production

A novel bimodal catalytic membrane reactor (BCMR) consisting of a Ru/γ-Al₂O₃/α-Al₂O₃ bimodal catalytic support and a silica separation layer was proposed. The catalytic activity of the support was successfully improved due to enhanced Ru dispersion by the increased specific surface area for the γ-Al₂O₃/α-Al₂O₃ bimodal structure. The silica separation layer was prepared via a sol–gel process, showing a H₂ permeance of 2.6 × 10⁻⁷ mol Pa⁻¹ m⁻² s⁻¹, with H₂/NH₃ and H₂/N₂ permeance ratios of 120 and 180 at 500 °C. The BCMR was applied to NH₃ decomposition for CO_x-free hydrogen production. When the reaction was carried out with a NH₃ feed flow rate of 40 ml min⁻¹ at 450 °C and the reaction pressure was increased from 0.1 to 0.3 MPa, NH₃ conversion decreased from 50.8 to 35.5% without H₂ extraction mainly due to the increased H₂ inhibition effect. With H₂ extraction, however, NH₃ conversion increased from 68.8 to 74.4% due to the enhanced driving force for H₂ permeation through the membrane.     

The influence of the CO inhibition effect on the estimation of the H2 purification unit surface

The CO inhibition effect on H₂ permeance through commercial Pd-based membranes was analysed by means of permeation measurements at different CO compositions (0–30% molar) and temperatures (593–723 K) with the aim to determine the increase of the membrane area in order to compensate the H₂ flux reduction owing to the CO inhibition effect. The permeance of H₂ fed with carbon monoxide was observed to decrease with respect to the case of pure hydrogen. At 647 K the H₂ permeance of a pure feed of 316 μmol m⁻² s⁻¹ Pa^−0.5 reduces progressively until 275 μmol m⁻² s⁻¹ Pa^−0.5 when 15% or more of CO is present in the system, until it reaches a plateau at 20%. The inhibition effect occurring when CO is present in the feed stream reduces with the progressive temperature increase; the reduction of the permeance decreases exponentially by 23% at 593 K and by 3% at 723 K with 10% of CO. The inhibition effect is seen to be reversible. An H₂ flux profile in a Sieverts' plot shows the effect produced by the increase of the CO composition along the Pd-based membrane length. The H₂ flux profile allows the area of a Pd-based membrane to be evaluated in order to have the same permeate flow rate of H₂ when it is fed with CO or as a pure stream. Moreover, a qualitative comparison between the H₂ flux profiles and a previously proposed model has been carried out.     

BaCe0.85Tb0.05Co0.1O3−δ perovskite hollow fibre membranes for hydrogen/oxygen permeation

Co-doped BaCe_0.85Tb_0.05Co_0.1O_3−δ (BCTCo) nanopowder was synthesized via a sol–gel method using ethylenediaminetetraacetic acid (EDTA) and citric acid as the chelating agents. Using the resultant powder, BCTCo perovskite hollow fibre membranes were then fabricated by the combined phase inversion and sintering technique. Properties of the BCTCo powder and the hollow fibre membranes in terms of crystalline phase, morphology, electrical conductivity, porosity, mechanical strength and hydrogen/oxygen permeation were investigated by a variety of characterization methods. The results indicated that doping of cobalt in the BCTb oxide led to a higher electrical conductivity and lower calcination temperature for the powder precursor to a perovskite structure as well as sintering temperature for the hollow fibre precursors to gastight membranes. In order to obtain gastight and robust hollow fibre membranes, the sintering temperature should be controlled between 1300 and 1450 °C. The maximum hydrogen flux through the BCTCo hollow fibre membranes reached up to 0.385 mL cm⁻² min⁻¹ at 1000 °C under 50% H₂–He/N₂ gradient, which is higher than that of the un-doped BCTb hollow fibre membranes with the same effective thickness, and especially much higher than that obtained from other proton conductors due to the asymmetric structure of the membrane designed. Moreover, the BCTCo hollow fibre membrane also exhibited noticeable oxygen permeation fluxes, i.e. 0.122 mL cm⁻² min⁻¹ at 1000 °C under the air/He gradient. However, doping of cobalt might damage the mechanical stability of the perovskite membranes in the hydrogen-containing atmosphere.     

Large impact of heating time on physical properties and photocatalytic H2 production of g-C3N4 nanosheets synthesized through urea polymerization in Ar atmosphere

The effect of heating time on the polymerization processes of urea into g-C₃N₄ nanosheets was studied in Ar atmosphere. It was found that heating time had a great influence on the crystalline quality, specific surface area (S_BET) and photocatalytic H₂ production of the obtained g-C₃N₄ nanosheets. G-C₃N₄ nanosheets with some degree of disorders in crystal structure were formed within 1 h at 550 °C, and these structural disorders maintained after 4 h, however disorders disappeared after extended heating of 6 h. G-C₃N₄ nanosheets with similar disorders in the crystal structure hold similar S_BET and exhibit comparable H₂ production rates. The highest H₂ production rate of 1.4 mmol h⁻¹ g⁻¹ occurs after 8 h heating, corresponding to 2.6% quantum efficiency at 420 nm.