Palladium composite membranes by electroless plating technique

Effect of air bubbling on electroless Pd plating for the practical application of hydrogen selective membranes

In this study, an air bubbling electroless plating (ELP) method was newly developed for the production of Pd composite membranes. The air bubble ELP alleviated the concentration polarization of Pd ions, making it possible to achieve a plating yield of 99.9% in 1 h and form very fine Pd grains with a uniform layer of ∼4.7 μm. A membrane with a diameter of 25.4 mm and a length of 450 mm was produced by the air bubbling ELP, achieving a hydrogen permeation flux of 4.0 × 10-1 mol m-2 s-1 and selectivity of ∼10 000 at 723 K with a pressure difference of 100 kPa. To confirm the reproducibility, six membranes were produced by the same method and assembled in a membrane reactor module to produce high-purity hydrogen by ammonia decomposition. Hydrogen permeation flux and selectivity of the six membranes at 723 K with a pressure difference of 100 kPa were 3.6 × 10-1 mol m-2 s-1 and ∼8900, respectively. An ammonia decomposition test with an ammonia feed rate of 12 000 mL min-1 showed that the membrane reactor produced hydrogen with >99.999% purity and a production rate of 1.01 Nm3 h-1 at 748 K with a retentate stream gauge pressure of 150 kPa and a permeation stream vacuum of -10 kPa. The ammonia decomposition tests confirmed that the newly developed air bubbling ELP method affords several advantages, such as rapid production, high ELP efficiency, reproducibility, and practical applicability.

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.

Electroless Plating of High-Performance Composite Pd Membranes with EDTA-Free Bath

High-performance composite Pd membranes were successfully fabricated using electroless plating with an EDTA-free bath. The plating started with employing the one-time addition of hydrazine. In the experiment, the hydrazine concentrations and plating bath volumes were systematically varied to optimize the plating. The optimum composite Pd membrane tube showed high H₂ permeance of 4.4 × 10⁻³ mol/m² s Pa^0.5 and high selectivity of 1.6 × 10⁴, but poor cycling stability. Then, a method of sequential addition of the hydrazine from the high to low concentrations was employed. The resultant membrane, about 6 μm thick, still exhibited a high selectivity of 6.8 × 10⁴ as well as a much-improved plating yield and cycling stability level; this membrane outperformed the membrane made using the unmodified plating technique with the EDTA-contained bath. This result indicates the EDTA-free bath combined with the sequential addition of hydrazine is a simple, low-cost, yet effective method for preparing thin, dense composite Pd membranes featuring high hydrogen permeation flux and high thermal durability.

Indirect (hydrogen-driven) electrodeposition of porous silver onto a palladium membrane

Hydrogen permeation through a pure palladium film (25 μm thickness, optically dense) is employed to trigger electron transfer (hydrogen-driven) reactions at the external palladium | aqueous electrolyte interface of a two-compartment electrochemical cell. Two systems are investigated to demonstrate feasibility for (i) indirect hydrogen-mediated silver electrodeposition with externally applied potential and (ii) indirect hydrogen-mediated silver electrodeposition driven by external formic acid decomposition. In both cases, porous metal deposits form as observed by optical and electron microscopies. Processes are self-limited as metal deposition blocks the palladium surface and thereby slows down further hydrogen permeation. The proposed methods could be employed for a wider range of metals, and they could provide an alternative (non-electrochemical or indirect) procedure for metal removal or metal recovery processes or for indirect metal sensing.

A Comprehensive Review on Hydrogen Absorption Behaviour of Metal Alloys Prepared through Mechanical Alloying

Hydride-forming alloys are currently considered reliable and suitable hydrogen storage materials because of their relatively high volumetric densities, and reversible H2 absorption/desorption kinetics, with high storage capacity. Nonetheless, their practical use is obstructed by several factors, including deterioration and slow hydrogen absorption/desorption kinetics resulting from the surface chemical action of gas impurities. Lately, common strategies, such as spark plasma sintering, mechanical alloying, melt spinning, surface modification and alloying with other elements have been exploited, in order to overcome kinetic barriers. Through these techniques, improvements in hydriding kinetics has been achieved, however, it is still far from that required in practical application. In this review, we provide a critical overview on the effect of mechanical alloying of various metal hydrides (MHs), ranging from binary hydrides (CaH2, MgH2, etc) to ternary hydrides (examples being Ti-Mn-N and Ca-La-Mg-based systems), that are used in solid-state hydrogen storage, while we also deliver comparative study on how the aforementioned alloy preparation techniques affect H2 absorption/desorption kinetics of different MHs. Comparisons have been made on the resultant material phases attained by mechanical alloying with those of melt spinning and spark plasma sintering techniques. The reaction mechanism, surface modification techniques and hydrogen storage properties of these various MHs were discussed in detail. We also discussed the remaining challenges and proposed some suggestions to the emerging research of MHs. Based on the findings obtained in this review, the combination of two or more compatible techniques, e.g., synthesis of metal alloy materials through mechanical alloying followed by surface modification (metal deposition, metal-metal co-deposition or fluorination), may provide better hydriding kinetics.

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.

Catalytic Sol Assisted Dense Pd/γ-Al2O3 Membrane using Modified Electroless Plating: Effect of Process on Surface Morphology

Palladium membranes are considered ideal for high purity hydrogen separation owing to their infinite selectivity to hydrogen. The key to such selectivity depends on the dense surface of the membrane that suggests absolute non-porous surface morphology. However, preparation of dense palladium membranes irrespective of any deposition technique leads to pit formation which makes synthesis of dense palladium membrane challenging. The current study illustrates the application of electroless plating assisted with novel catalytic sol pre-coating to prepare dense Pd membranes. The surface characterization using field emission scanning electron microscope (FESEM) and atomic force microscopy (AFM) were performed to identify the gaps between dip coating and electroless plating. It was observed that with the use of a dip coated catalytic sol, thinner and well dispersed Pd deposits could be prepared. The porosity of deposited Pd layers does not affect the essential densification property as sol surface underneath dispersed Pd remains dense.

Fabrication of a metal membrane on a perforated polymer substrate by palladium aerosol activation and subsequent electroless plating

Fabrication of a metal membrane on a perforated flexible poly(tetrafluoroethylene) (PTFE) substrate was developed by employing spark-generated palladium (Pd) aerosol activation and the subsequent electroless plating of Pd. After aerosol activation, Pd agglomerates of spark-generated primary particles (approximately 2.6 nm in diameter) with a face-centered-cubic structure were deposited uniformly on the PTFE substrate. Homogeneous Pd particles with an average size of 188 nm were tightly packed together to form a Pd membrane after Pd plating. The average plating rate of Pd during 30 min of plating at an activation intensity of 25 microg/cm(2) was 14.2 microg/cm(2) x min.

Thin composite palladium and palladium/alloy membranes for hydrogen separation

Dense composite Pd and Pd/alloy membranes are currently being extensively investigated. The synthesis and characterization of these membranes, with a special emphasis on Pd/alloy membranes, are reviewed in this paper. Experimental results on Pd/Cu membranes supported on porous stainless steel exhibited good thermal stability and reasonable hydrogen flux. Furthermore, optical micrographs showed the formation of the dense palladium layer was unaffected by the topological features of the porous stainless steel, although the surface of the support directs the topology of the final Pd layer.