State-of-the-Art of Supported Metal Membranes for Gas Separation

Ammonia Synthesis at Ambient Conditions via Electrochemical Atomic Hydrogen Permeation

Direct electrochemical nitrogen reduction holds the promise of enabling the production of carbon emission-free ammonia, which is an important intermediate in the fertilizer industry and a potential green energy carrier. Here we show a strategy for ambient condition ammonia synthesis using a hydrogen permeable nickel membrane/electrode that spatially separates the electrolyte and hydrogen reduction side from the dinitrogen activation and hydrogenation sites. Gaseous ammonia is produced catalytically in the absence of electrolyte via hydrogenation of adsorbed nitrogen by electrochemically permeating atomic hydrogen from water reduction. Dinitrogen activation at the polycrystalline nickel surface is confirmed with ¹⁵N₂ isotope labeling experiments, and it is attributed to a Mars-van Krevelen mechanism enabled by the formation of N-vacancies upon hydrogenation of surface nitrides. We further show that gaseous hydrogen does not hydrogenate the adsorbed nitrogen, strengthening the benefit of having an atomic hydrogen permeable electrode. The proposed approach opens new directions toward green ammonia.

Synthesis, Electrocatalytic and Gas Transport Characteristics of Pentagonally Structured Star-Shaped Nanocrystallites of Pd-Ag

The method of synthesis of bimetallic Pd-Ag pentagonally structured catalyst "nanostar" on the surface of Pd-23%Ag alloy films has been developed. The resulting catalyst was studied as a highly active functional layer for methanol oxidation reaction (MOR) in alkaline media and the intensification of hydrogen transport through the Pd-23%Ag membrane in the processes of hydrogen diffusion purification. A modifying layer with a controlled size, composition and excellent electrocatalytic activity was synthesized by electrochemical deposition at a reduced current density compared to classical methods. The low deposition rate affects the formation of pentagonally structured nanocrystallites, allowing Pd and Ag particles to form well-defined structures due to the properties of the surfactant used. Electrochemical studies have demonstrated that the catalyst synthesized by the "nanostar" method shows better electrocatalytic activity in relation to MOR and demonstrates a higher peak current (up to 17.82 µA cm^-2) in comparison with one for the catalyst synthesized by the "nanoparticle" method (up to 10.66 µA cm^-2) in a cyclic voltammetric study. The nanostar catalyst electrode releases the highest current density (0.25 µA cm^-2) for MOR and demonstrates higher catalytic activity for the oxidation of possible intermediates such as sodium formate in MOR. In the processes of diffusion membrane purification of hydrogen, a multiple increase in the density of the penetrating flux of hydrogen through the membranes modified by the "nanostar" catalyst (up to 10.6 mmol s^-1 m^-2) was demonstrated in comparison with the membranes modified by the "nanoparticles" method (up to 4.49 mmol s^-1 m^-2). Research data may indicate that the properties of the developed pentagonally structured catalyst "nanostar" and its enhanced activity with respect to reactions involving hydrogen increase the desorption activity of the membrane, which ultimately accelerates the overall stepwise transfer of hydrogen across the membrane.

Prospecting Stress Formed by Hydrogen or Isotope Diffused in Palladium Alloy Cathode

The objective of this project is to take into account the mechanical constraints formed by diffusion of hydrogen or tritium in watertight palladium alloy cathode. To know the origin of these, it was necessary to discriminating the damaging effects encountered. Effectively, hydrogen and isotope induce deformation, embrittlement, stress corrosion cracking and cathodic corrosion in different regions of cathode. Palladium can be alloyed with silver or yttrium to favourably increase diffusion and reduce these constraints. Effects of electrochemical factors, temperature, cathode structure, adsorbed transient complex of palladium and porous material support are given to estimate and to limit possible damage.

New Insight to the Effects of Heat Treatment in Air on the Permeation Properties of Thin Pd77%Ag23% Membranes

Sputtered Pd77%Ag23% membranes of thickness 2.2–8.5 µm were subjected to a three-step heat treatment in air (HTA) to investigate the relation between thickness and the reported beneficial effects of HTA on hydrogen transport. The permeability experiments were complimented by volumetric hydrogen sorption measurements and atomic force microscopy (AFM) imaging in order to relate the observed effects to changes in hydrogen solubility and/or structure. The results show that the HTA—essentially an oxidation-reduction cycle—mainly affects the thinner membranes, with the hydrogen flux increasing stepwise upon HTA of each membrane side. The hydrogen solubility is found to remain constant upon HTA, and the change must therefore be attributed to improved transport kinetics. The HTA procedure appears to shift the transition from the surface to bulk-limited transport to lower thickness, roughly from ~5 to ≤2.2 µm under the conditions applied here. Although the surface topography results indicate that HTA influences the surface roughness and increases the effective membrane surface area, this cannot be the sole explanation for the observed hydrogen flux increase. This is because considerable surface roughening occurs during hydrogen permeation (no HTA) as well, but not accompanied by the same hydrogen flux enhancement. The latter effect is particularly pronounced for thinner membranes, implying that the structural changes may be dependent on the magnitude of the hydrogen flux.

Grain Boundary Segregation in Pd-Cu-Ag Alloys for High Permeability Hydrogen Separation Membranes

Dense metal membranes that are based on palladium (Pd) are promising for hydrogen separation and production due to their high selectivity and permeability. Optimization of alloy composition has normally focused on bulk properties, but there is growing evidence that grain boundaries (GBs) play a crucial role in the overall performance of membranes. The present study provides parameters and analyses of GBs in the ternary Pd-Ag-Cu system, based on first-principles electronic structure calculations. The segregation tendency of Cu, Ag, and vacancies towards 12 different coherent ∑ GBs in Pd was quantified using three different procedures for relaxation of supercell lattice constants, representing the outer bounds of infinitely elastic and stiff lattice around the GBs. This demonstrated a clear linear correlation between the excess volume and the GB energy when volume relaxation was allowed for. The point defects were attracted by most of the GBs that were investigated. Realistic atomic-scale models of binary Pd-Cu and ternary Pd-Cu-Ag alloys were created for the ∑5(210) boundary, in which the strong GB segregation tendency was affirmed. This is a starting point for more targeted engineering of alloys and grain structure in dense metal membranes and related systems.

Recent Advances in Pd-Based Membranes for Membrane Reactors

Palladium-based membranes for hydrogen separation have been studied by several research groups during the last 40 years. Much effort has been dedicated to improving the hydrogen flux of these membranes employing different alloys, supports, deposition/production techniques, etc. High flux and cheap membranes, yet stable at different operating conditions are required for their exploitation at industrial scale. The integration of membranes in multifunctional reactors (membrane reactors) poses additional demands on the membranes as interactions at different levels between the catalyst and the membrane surface can occur. Particularly, when employing the membranes in fluidized bed reactors, the selective layer should be resistant to or protected against erosion. In this review we will also describe a novel kind of membranes, the pore-filled type membranes prepared by Pacheco Tanaka and coworkers that represent a possible solution to integrate thin selective membranes into membrane reactors while protecting the selective layer. This work is focused on recent advances on metallic supports, materials used as an intermetallic diffusion layer when metallic supports are used and the most recent advances on Pd-based composite membranes. Particular attention is paid to improvements on sulfur resistance of Pd based membranes, resistance to hydrogen embrittlement and stability at high temperature.

Integration of Methane Steam Reforming and Water Gas Shift Reaction in a Pd/Au/Pd-Based Catalytic Membrane Reactor for Process Intensification

Palladium-based catalytic membrane reactors (CMRs) effectively remove H₂ to induce higher conversions in methane steam reforming (MSR) and water-gas-shift reactions (WGS). Within such a context, this work evaluates the technical performance of a novel CMR, which utilizes two catalysts in series, rather than one. In the process system under consideration, the first catalyst, confined within the shell side of the reactor, reforms methane with water yielding H₂, CO and CO₂. After reforming is completed, a second catalyst, positioned in series, reacts with CO and water through the WGS reaction yielding pure H₂O, CO₂ and H₂. A tubular composite asymmetric Pd/Au/Pd membrane is situated throughout the reactor to continuously remove the produced H₂ and induce higher methane and CO conversions while yielding ultrapure H₂ and compressed CO₂ ready for dehydration. Experimental results involving (i) a conventional packed bed reactor packed (PBR) for MSR, (ii) a PBR with five layers of two catalysts in series and (iii) a CMR with two layers of two catalysts in series are comparatively assessed and thoroughly characterized. Furthermore, a comprehensive 2D computational fluid dynamics (CFD) model was developed to explore further the features of the proposed configuration. The reaction was studied at different process intensification-relevant conditions, such as space velocities, temperatures, pressures and initial feed gas composition. Finally, it is demonstrated that the above CMR module, which was operated for 600 h, displays quite high H₂ permeance and purity, high CH₄ conversion levels and reduced CO yields.

Improved benzene production from methane dehydroaromatization over Mo/HZSM-5 catalysts via hydrogen-permselective palladium membrane reactors

Catalytic Pd membrane reactors improve C₆H₆ yield compared to fixed-bed reactors.

Direct observation of the surface segregation of Cu in Pd by time-resolved positron-annihilation-induced Auger electron spectroscopy

Density functional theory calculations predict the surface segregation of Cu in the second atomic layer of Pd which has not been unambiguously confirmed by experiment so far. We report measurements on Pd surfaces covered with three and six monolayers of Cu using element selective positron-annihilation-induced Auger electron spectroscopy (PAES) which is sensitive to the topmost atomic layer. Moreover, time-resolved PAES, which was applied for the first time, enables the investigation of the dynamics of surface atoms and hence the observation of the segregation process. The time constant for segregation was experimentally determined to τ=1.38(0.21)  h, and the final segregated configuration was found to be consistent with calculations. Time-dependent PAES is demonstrated to be a novel element selective technique applicable for the investigation of, e.g., heterogeneous catalysis, corrosion, or surface alloying.