Preparation and characterization of ceramic supported ultra-thin (~1 µm) Pd-Ag membranes

Advances and Perspectives of H2 Production from NH3 Decomposition in Membrane Reactors

Hydrogen is often regarded as an ideal energy carrier. Its use in energy conversion devices does in fact not produce any pollutants. However, due to challenges related to its transportation and storage, liquid hydrogen carriers are being investigated. Among the liquid hydrogen carriers, ammonia is considered very promising because it is easy to store and transport, and its conversion to hydrogen has only nitrogen as a byproduct. This work focuses on a review of the latest results of studies dealing with ammonia decomposition for hydrogen production. After a general introduction to the topic, this review specifically focuses on works presenting results of membrane reactors for ammonia decomposition, particularly describing the different reactor configurations and operating conditions, membrane properties, catalysts, and purification steps that are required to achieve pure hydrogen for fuel cell applications.

Hydrogen Permeability of Composite Pd-Au/Pd-Cu Membranes and Methods for Their Preparation

Thin Pd-40%Cu films were obtained via the classical melting and rolling method, magnetron sputtering, and modified with nanostructured functional coatings to intensify the process of hydrogen transportation. The films were modified by electrodeposition, according to the classical method of obtaining palladium black and "Pd-Au nanoflowers" with spherical and pentagonal particles, respectively. The experiment results demonstrated the highest catalytic activity (89.47 mA cm^-2), good resistance to CO poisoning and long-term stability of Pd-40%Cu films with a pentagonal structured coating. The investigation of the developed membranes in the hydrogen transport processes in the temperature range of 25-300 °C also demonstrated high and stable fluxes of up to 475.28 mmol s^-1 m^-2 (deposited membranes) and 59.41 mmol s^-1 m^-2 (dense metal membranes), which were up to 1.5 higher, compared with membrane materials with classic niello. For all-metal modified membranes, the increase in flux was up to sevenfold, compared with a smooth membrane made of pure palladium, and for deposited films, this difference was manyfold. The membrane materials' selectivity was also high, up to 4419. The developed strategy for modifying membrane materials with functional coatings of a fundamentally new complex geometry can shed new light on the development and fabrication of durable and highly selective palladium-based membranes for gas steam reformers.

Palladium Membrane with High Density of Large-Angle Grain Boundaries to Promote Hydrogen Diffusivity

A higher density of large-angle grain boundaries in palladium membranes promotes hydrogen diffusion whereas small-angle grain boundaries suppress it. In this paper, the microstructure formation in 10 µm thick palladium membranes is tuned to achieve a submicronic grain size above 100 nm with a high density of large-angle grain boundaries. Moreover, changes in the grain boundaries’ structure is investigated after exposure to hydrogen at 300 and 500 °C. To attain large-angle grain boundaries in Pd, the coating was performed on yttria-stabilized zirconia/porous Crofer 22 APU substrates (intended for use later in an ultracompact membrane reactor). Two techniques of plasma sprayings were used: suspension plasma spraying using liquid nano-sized powder suspension and vacuum plasma spraying using microsized powder as feedstock. By controlling the process parameters in these two techniques, membranes with a comparable density of large-angle grain boundaries could be developed despite the differences in the fabrication methods and feedstocks. Analyses showed that a randomly oriented submicronic structure could be attained with a very similar grain sizes between 100 and 500 nm which could enhance hydrogen permeation. Exposure to hydrogen for 72 h at high temperatures revealed that the samples maintained their large-angle grain boundaries despite the increase in average grain size to around 536 and 720 nm for vacuum plasma spraying and suspension plasma spraying, respectively.

Versatile and Resistant Electroless Pore-Plated Pd-Membranes for H2-Separation: Morphology and Performance of Internal Layers in PSS Tubes

Pd-membranes are interesting in multiple ultra-pure hydrogen production processes, although they can suffer inhibition by certain species or abrasion under fluidization conditions in membrane reactors, thus requiring additional protective layers to ensure long and stable operation. The ability to incorporate intermediate and palladium films with enough adherence on both external and internal surfaces of tubular porous supports becomes crucial to minimize their complexity and cost. This study addresses the incorporation of CeO₂ and Pd films onto the internal side of PSS tubes for applications in which further protection could be required. The membranes so prepared, with a Pd-thickness around 12–15 μm, show an excellent mechanical resistance and similar performance to those prepared on the external surface. A good fit to Sieverts’ law with an H₂-permeance of 4.571 × 10⁻³ mol m⁻² s⁻¹ Pa^−0.5 at 400 °C, activation energy around 15.031 kJ mol⁻¹, and complete ideal perm-selectivity was observed. The permeate fluxes reached in H₂ mixtures with N₂, He, or CO₂ decreased with dilution and temperature due to the inherent concentration-polarization. The presence of CO in mixtures provoked a higher decrease because of a further inhibition effect. However, the original flux was completely recovered after feeding again with pure hydrogen, maintaining stable operation for at least 1000 h.

Modeling of H2 Permeation through Electroless Pore-Plated Composite Pd Membranes Using Computational Fluid Dynamics

This work focused on the computational fluid dynamics (CFD) modeling of H₂/N₂ separation in a membrane permeator module containing a supported dense Pd-based membrane that was prepared using electroless pore-plating (ELP-PP). An easy-to-implement model was developed based on a source–sink pair formulation of the species transport and continuity equations. The model also included the Darcy–Forcheimer formulation for modeling the porous stainless steel (PSS) membrane support and Sieverts’ law for computing the H₂ permeation flow through the dense palladium film. Two different reactor configurations were studied, which involved varying the hydrogen flow permeation direction (in–out or out–in). A wide range of experimental data was simulated by considering the impact of the operating conditions on the H₂ separation, such as the feed pressure and the H₂ concentration in the inlet stream. Simulations of the membrane permeator device showed an excellent agreement between the predicted and experimental data (measured as permeate and retentate flows and H₂ separation). Molar fraction profiles inside the permeator device for both configurations showed that concentration polarization near the membrane surface was not a limit for the hydrogen permeation but could be useful information for membrane reactor design, as it showed the optimal length of the reactor.

Proton conducting membranes for hydrogen and ammonia production

Dense proton conducting membranes possess 100% hydrogen selectivity and excellent stability under practical conditions, and serve as promising technologies for hydrogen and ammonia production.

Effective H2 Separation through Electroless Pore-Plated Pd Membranes Containing Graphite Lead Barriers

Hydrogen promotion as a clean energy vector could provide an efficient strategy for realizing real decarbonization of the current energy system. Purification steps are usually required in most H₂-production processes, providing the use of Pd-based membranes, particularly those supported on porous stainless steel (PSS), important advantages against other alternatives. In this work, new composite membranes were prepared by modifying PSS supports with graphite, as an intermediate layer, before incorporating a palladium film by electroless pore-plating. Fully dense Pd layers were reached, with an estimated thickness of around 17 μm. Permeation measurements were carried out in two different modes: H₂ permeation from the inner to the outer side of the membrane (in-out) and in the opposite way (out-in). H₂ permeances between 3.24 × 10^-4 and 4.33 × 10^-4 mol m^-2 s^-1 Pa^-0.5 with α_H2/N2 ≥ 10,000 were reached at 350-450 °C when permeating from the outer to the inner surface. Despite a general linear trend between permeating H₂ fluxes and pressures, the predicted intercept in (0,0) by the Sieverts' law was missed due to the partial Pd infiltration inside the pores. H₂-permeances progressively decreased up to around 33% for binary H₂-N₂ mixtures containing 40 vol% N₂ due to concentration-polarization phenomena. Finally, the good performance of these membranes was maintained after reversing the direction of the permeate flux. This fact practically demonstrates an adequate mechanical resistance despite generating tensile stress on the Pd layer during operation, which is not accomplished in other Pd membranes.

Microstructural Investigation and On-Site Repair of Thin Pd-Ag Alloy Membranes

Pd membranes act in an important role in H2 purification and H2 production in membrane reactors. Pd-Ag alloy membranes fabricated by consecutive electroless- and electroplating process on alumina tubes exhibited good stability under stringent heating/cooling cycles at a ramp rate of 10 K/min, imitating practical fast initiation or emergency shutdown conditions. Bilayer Pd-Ag membranes can form dense and uniform alloy after thermal treatment for 24 h at 823 K under H2 atmosphere, despite a porous structure due to the development of liquid-like properties above Tamman temperature to enforce the migrativity. On the contrary, alloying under N2 atmosphere resulted in a Pd-enriched layer. This led to a lower H2 flux but superior thermal stability compared to that alloying under H2 atmosphere. The trilayer approach of electroless-plated Pd, electro-polated Ag and electroless-plated Pd is not suitable to achieve homogeneous Pd-Ag alloys, which, on the other hand, presented the occurrence of a small gap between top Pd layer and middle Ag layer, probably due to insufficient wetting during plating process. An on-site repair treatment in analogous to MOCVD (Metal-organic Chemical Vapor Deposition) process was first proposed to extend the lifetime of Pd-Ag membrane, i.e., by vaporizing, and subsequent decomposition of Ag(OOCC2F5) powders to "preferentially" block the pinholes under vacuum and at working temperature of ca. 473-673 K, which effectively reduced the N2 flux by 57.4% compared to the initial value. The H2 flux, however, declined by 16.7% due to carbon deposition on the membrane surface, which requires further investigation. This approach shows some potential for on-site repair without disassembly or cooling to room temperature.

Understanding of transition metal (Ru, W) doping into Nb for improved thermodynamic stability and hydrogen permeability: density functional theory calculations

Hydrogen solubility and diffusivity are the key features of hydrogen permeable membrane materials. To characterize the hydrogen permeation performance of NbTM (TM = W, Ru) phases, their hydrogen diffusion coefficient and solution coefficient, thermodynamic stability and chemical bonding are studied by a series of first principles calculations. The phonon spectra and elastic constants show that NbTM is dynamically stable. The TM-H chemical bonds have an ionic/covalent mixed character and are stronger than the Nb-H bond. The preferential diffusion paths of H in both Nb₁₆H and Nb₁₅TMH are from a tetrahedral interstitial site (TIS) to another TIS. The TM doping in Nb₁₆H lowers the solubility and energy barrier of H diffusion and enhances the H diffusion coefficient (D), with Nb₁₆RuH exhibiting the highest D value for TIS to TIS diffusion (2.14 × 10^-8 m² s^-1) at 600 K. This study shows that alloying and temperature could significantly affect the solubility and diffusivity of hydrogen in Nb. Moreover, TM doping could greatly improve the hydrogen diffusion performance with good control of hydrogen embrittlement.

Recent Developments in Compact Membrane Reactors with Hydrogen Separation

Hydrogen production and storage in small and medium scale, and chemical heat storage from renewable energy, are of great interest nowadays. Micro-membrane reactors for reforming of methane, as well as for the dehydrogenation of liquid organic hydrogen carriers (LOHCs), have been developed. The systems consist of stacked plates with integrated palladium (Pd) membranes. As an alternative to rolled and electroless plated (Pd) membranes, the development of a cost-effective method for the fabrication of Pd membranes by suspension plasma spraying is presented.

A remarkable two-dimensional membrane for multifunctional gas separation: halogenated metal-free fused-ring polyphthalocyanine

We theoretically explore the structural and mechanical properties of metal-free fused-ring polyphthalocyanine (H2PPc) and halogenated H2PPc (F-H2PPc and Cl-H2PPc) membranes, and the energy profiles for gaseous H2, CO, CH4, CO2 and N2 molecules adsorbing on and passing through these monolayers. Importantly, we reconsider in depth the values of the parameters in the definition of permeance, and corroborate the validity of the model from first-principles theory with the results of H2 diffusion from classic molecular dynamics simulations. With well-defined nanosized pores, halogenated H2PPc monolayers turn out to be multifunctional gas separation membranes, i.e. F-H2PPc for H2/CO, H2/CH4, CO2/N2, CO2/CH4, CO/CH4 and N2/CH4 separation as well as Cl-H2PPc for H2/CO, H2/CH4 and H2/CO2 separation, which should be of great potential in energy and environmental fields.

Review of Supported Pd-Based Membranes Preparation by Electroless Plating for Ultra-Pure Hydrogen Production

In the last years, hydrogen has been considered as a promising energy vector for the oncoming modification of the current energy sector, mainly based on fossil fuels. Hydrogen can be produced from water with no significant pollutant emissions but in the nearest future its production from different hydrocarbon raw materials by thermochemical processes seems to be more feasible. In any case, a mixture of gaseous compounds containing hydrogen is produced, so a further purification step is needed to purify the hydrogen up to required levels accordingly to the final application, i.e., PEM fuel cells. In this mean, membrane technology is one of the available separation options, providing an efficient solution at reasonable cost. Particularly, dense palladium-based membranes have been proposed as an ideal chance in hydrogen purification due to the nearly complete hydrogen selectivity (ideally 100%), high thermal stability and mechanical resistance. Moreover, these membranes can be used in a membrane reactor, offering the possibility to combine both the chemical reaction for hydrogen production and the purification step in a unique device. There are many papers in the literature regarding the preparation of Pd-based membranes, trying to improve the properties of these materials in terms of permeability, thermal and mechanical resistance, poisoning and cost-efficiency. In this review, the most relevant advances in the preparation of supported Pd-based membranes for hydrogen production in recent years are presented. The work is mainly focused in the incorporation of the hydrogen selective layer (palladium or palladium-based alloy) by the electroless plating, since it is one of the most promising alternatives for a real industrial application of these membranes. The information is organized in different sections including: (i) a general introduction; (ii) raw commercial and modified membrane supports; (iii) metal deposition insights by electroless-plating; (iv) trends in preparation of Pd-based alloys, and, finally; (v) some essential concluding remarks in addition to futures perspectives.