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

Hydrogen Separation Membranes: A Material Perspective

The global energy market is shifting toward renewable, sustainable, and low-carbon hydrogen energy due to global environmental issues, such as rising carbon dioxide emissions, climate change, and global warming. Currently, a majority of hydrogen demands are achieved by steam methane reforming and other conventional processes, which, again, are very carbon-intensive methods, and the hydrogen produced by them needs to be purified prior to their application. Hence, researchers are continuously endeavoring to develop sustainable and efficient methods for hydrogen generation and purification. Membrane-based gas-separation technologies were proven to be more efficient than conventional technologies. This review explores the transition from conventional separation techniques, such as pressure swing adsorption and cryogenic distillation, to advanced membrane-based technologies with high selectivity and efficiency for hydrogen purification. Major emphasis is placed on various membrane materials and their corresponding membrane performance. First, we discuss various metal membranes, including dense, alloyed, and amorphous metal membranes, which exhibit high hydrogen solubility and selectivity. Further, various inorganic membranes, such as zeolites, silica, and CMSMs, are also discussed. Major emphasis is placed on the development of polymeric materials and membranes for the selective separation of hydrogen from CH4, CO2, and N2. In addition, cutting-edge mixed-matrix membranes are also delineated, which involve the incorporation of inorganic fillers to improve performance. This review provides a comprehensive overview of advancements in gas-separation membranes and membrane materials in terms of hydrogen selectivity, permeability, and durability in practical applications. By analyzing various conventional and advanced technologies, this review provides a comprehensive material perspective on hydrogen separation membranes, thereby endorsing hydrogen energy for a sustainable future.

Nano-enabled gas separation membranes: Advancing sustainability in the energy-environment Nexus

Gas separation membranes serve as crucial to numerous industrial processes, including gas purification, energy production, and environmental protection. Recent advancements in nanomaterials have drastically revolutionized the process of developing tailored gas separation membranes, providing unreachable levels of control over the performance and characteristics of the membrane. The incorporation of cutting-edge nanomaterials into the composition of traditional polymer-based membranes has provided novel opportunities. This review critically analyses recent advancements, exploring the diverse types of nanomaterials employed, their synthesis techniques, and their integration into membrane matrices. The impact of nanomaterial incorporation on separation efficiency, selectivity, and structural integrity is evaluated across various gas separation scenarios. Furthermore, the underlying mechanisms behind nanomaterial-enhanced gas transport are examined, shedding light on the intricate interactions between nanoscale components and gas molecules. The review also discusses potential drawbacks and considerations associated with nanomaterial utilization in membrane development, including scalability and long-term stability. This review article highlights nanomaterials' significant impact in revolutionizing the field of selective gas separation membranes, offering the potential for innovation and future directions in this ever-evolving sector.

Development of inorganic and mixed matrix membranes for application in toxic dyes-contaminated industrial effluents with in-situ treatments

Dyes are the most ubiquitous organic pollutants in industrial effluents. They are highly toxic to both plants and animals; thus, their removal is paramount to the sustainability of ecosystem. However, they have shown resistance to photolysis and various biological, physical, and chemical wastewater remediation processes. Membrane removal technology has been vital for the filtration/separation of the dyes. In comparison to polymeric membranes, inorganic and mixed matrix (MM) membranes have shown potentials to the removal of dyes. The inorganic and MM membranes are particularly effective due to their high porosity, enhanced stability, improved permeability, higher enhanced selectivity and good stability and resistance to harsh chemical and thermal conditions. They have shown prospects in filtration/separation, adsorption, and catalytic degradation of the dyes. This review highlighted the advantages of the inorganic and MM membranes for the various removal techniques for the treatments of the dyes. Methods for the membranes production have been reviewed. Their application for the filtration/separation and adsorption have been critically analyzed. Their application as support for advanced oxidation processes such as persulfate, photo-Fenton and photocatalytic degradations have been highlighted. The mechanisms underscoring the efficiency of the processes have been cited. Lastly, comments were given on the prospects and challenges of both inorganic and MM membranes towards removal of the dyes from industrial effluents.

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.

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.

Design of Laboratory Stand for Displacement Measurement of IPMC Actuators

The polymer technology based on Electroactive polymers and metal composite ionic polymer has great potential and advantages in many engineering fields. In this paper, a laboratory stand for testing Ionic polymer-metal composites (IPMC) is presented. The laboratory station includes a power supply system and a measuring system for the displacement of IPMC composites. Tests and measurements are carried out using a laser transducer and a camera equipped with image analysis software to determine the IPMC strips displacement. The experimental investigation of IPMCs under different voltage supplies and waveforms, environmental working humidity conditions, temperature, and loading conditions has proved the significant influence of geometric dimension and the effect of increased stress on the displacement value. For materials powered by a higher voltage value, an increased deflection value was noted. In case of displacement, longer is the sample, higher is the displacement value. The length of the sample under load, affects adversely its performance, resulting in an increase in the load on the sample. For samples of a thick size, a more stable movement with and without load can be noticed.

Hydrogen and Deuterium Solubility, Diffusivity and Permeability from Sorption Measurements in the Ni33Ti39Nb28 Alloy

The hydrogen/deuterium sorption properties of Ni₃₃Ti₃₉Nb₂₈ synthesized by the vacuum induction melting technique were measured between 400 and 495 °C for pressure lower than 3 bar. The Sieverts law is valid up to H(D)/M < 0.2 in its ideal form; the absolute values of the hydrogenation/deuteration enthalpy are ΔH(H₂) = 85 ± 5 kJ/mol and ΔH(D₂) = 84 ± 4 kJ/mol. From the kinetics of absorption, the diffusion coefficient was derived, and an Arrhenius dependence from the temperature was obtained, with E_a,d = 12 ± 1 kJ/mol for both hydrogen isotopes. The values of the alloy permeability, obtained by combining the solubility and the diffusion coefficient, were of the order of 10^-9 mol m^-1 s^-1 Pa^-0.5, a value which is one order of magnitude lower than that of Ni₄₁Ti₄₂Nb₁₇, until now the best Ni-Ti-Nb alloy for hydrogen purification. In view of the simplicity of the technique here proposed to calculate the permeability, this method could be used for the preliminary screening of new alloys.

Graphene-Coated Halloysite Nanoclay Membrane for the Enhanced Separation of Hydrogen from a Hydrogen-Helium Mixture

This study highlights the separation of hydrogen from H₂-He mixture gas by a graphene-coated halloysite nanoclay membrane. The graphene-coated clay membrane along with its pure clay counterpart is successfully developed and studied for gas separation using hydrogen (H₂)-helium (He) single and mixture gases. Hydrothermal and nonhydrothermal methods were applied for the synthesis of a ″coated″ membrane on a porous alumina substrate from the graphene and halloysite clay. To date, nanoporous zeolites are the potential materials for gas separation based on a molecular sieving mechanism. A similar separation mechanism for hydrogen and helium from mixture gases may not work efficaciously due to the closeness of their kinetic diameter (H₂: 2.89 Å and He: 2.6 Å). The presence of defects and torn nanopores between graphene layers along with the different surface charges of the inner and outer layer of halloysite nanotubes facilitates the ″coated″ membrane to show an appreciable H₂/He separation factor of ∼4 using H₂-He (1:1) mixture gas compared to 2.86 for the pure halloysite membrane. The available charge layer of graphene also has a significant contribution for this increased H₂/He selectivity value. The permeate flux of H₂ and He through both the graphene-coated clay membrane and pure clay membrane has also been noted. The permeate flux of pure H₂ and He was 2 × 10^-7 and 1.3 × 10^-7 mol m^-2 s^-1 Pa^-1 for the clay membrane, whereas for the ″coated″ clay membrane, the values changed to 0.1 × 10^-7 and ∼0.05 × 10^-7 mol m^-2 s^-1 Pa^-1 at 100 kPa, respectively.

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.

Surface Optimization of Commercial Porous Ti Substrates by EPD of Titanium Nitride

In this work, the infiltration of TiN powders by electrophoretic deposition (EPD) in aqueous media was considered as alternative method to reduce the size craters and the roughness of commercial porous Ti substrates. Ti substrates can be used as suitable supports for the deposition of dense hydrogen separation TiNx-based membranes by physical vapor deposition (PVD) techniques. The influence of various EPD deposition parameters on surface morphology and roughness of TiN-infiltrated substrates were investigated in order to optimize their surface properties. The results suggest that a multi-step EPD procedure is an effective technique for reducing substrate surface defects of commercial porous Ti substrates which could then be successfully used as proper supports for the deposition of dense and defect-free TiNx layers, also aligning the thermal mismatch between the active layer and the porous substrate.

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.

Gas-Transport Characteristics of PdCu–Nb–PdCu Membranes Modified with Nanostructured Palladium Coating

A method for obtaining composite gas-diffusion PdCu–Nb–PdCu membranes modified with a nanostructured crystalline coating was developed to increase the performance of Nb-based membranes. A modifying functional layer with a controlled size and composition was synthesized by electrochemical deposition, which made it possible to determine a certain geometric shape for palladium nanocrystallites. Developed PdCu–Nb–PdCu membranes have demonstrated flux values up to 0.232 mmol s⁻¹ m⁻² in the processes of diffusion purification of hydrogen at 400 °C. A very significant difference in the hydrogen fluxes through the modified and non-modified composite PdCu–Nb–PdCu membranes reached 1.73 times at the lower threshold temperature of 300 °C. Cu doping of protective layer did not affect the selective properties of the membranes, which was confirmed by the obtained high selectivity values up to 1323, and made it possible to reduce the noble metal content. The research data indicate that the modification of the membrane surface significantly accelerates the hydrogen transfer process at sufficiently low temperatures due to the acceleration of dissociative–associative processes on the surface. The reported approach demonstrates new possibilities for creating productive and cost-efficient membranes based on niobium.

Recent Advances in Catalysts and Membranes for MCH Dehydrogenation: A Mini Review

Methylcyclohexane (MCH), one of the liquid organic hydrogen carriers (LOHCs), offers a convenient way to store, transport, and supply hydrogen. Some features of MCH such as its liquid state at ambient temperature and pressure, large hydrogen storage capacity, its well-known catalytic endothermic dehydrogenation reaction and ease at which its dehydrogenated counterpart (toluene) can be hydrogenated back to MCH and make it one of the serious contenders for the development of hydrogen storage and transportation system of the future. In addition to advances on catalysts for MCH dehydrogenation and inorganic membrane for selective and efficient separation of hydrogen, there are increasing research interests on catalytic membrane reactors (CMR) that combine a catalyst and hydrogen separation membrane together in a compact system for improved efficiency because of the shift of the equilibrium dehydrogenation reaction forwarded by the continuous removal of hydrogen from the reaction mixture. Development of efficient CMRs can serve as an important step toward commercially viable hydrogen production systems. The recently demonstrated commercial MCH-TOL based hydrogen storage plant, international transportation network and compact hydrogen producing plants by Chiyoda and some other companies serves as initial successful steps toward the development of full-fledged operation of manufacturing, transportation and storage of zero carbon emission hydrogen in the future. There have been initiatives by industries in the development of compact on-board dehydrogenation plants to fuel hydrogen-powered locomotives. This review mainly focuses on recent advances in different technical aspects of catalytic dehydrogenation of MCH and some significant achievements in the commercial development of MCH-TOL based hydrogen storage, transportation and supply systems, along with the challenges and future prospects.

Reactors for Process Intensification: Recent Advances and Key Applications

Coupling industrial development and environmental protection is one of the most important challenges for the coming years [...].

Hydrogen Separation Performance of UiO-66-NH2 Membranes Grown via Liquid-Phase Epitaxy Layer-by-Layer Deposition and One-Pot Synthesis

The quality assurance of hydrogen fuel for mobile applications is assessed by the guidelines and directives given in the European and international standards. However, the presence of impurities in the hydrogen fuel, in particular nitrogen, water, and oxygen, is experienced in several refueling stations. Within this work, metal-organic framework (MOF)-based membranes are investigated as a fine-purification stage of the hydrogen fuel. Three H₂/N₂ concentrations have been used to analyze the separation factor of UiO-66-NH₂ membranes prepared using the layer-by-layer (LBL) and the one-pot (OP) synthesis methods. It is shown that the separation factor for an equimolar ratio is 14.4% higher for the LBL sample compared to the OP membrane, suggesting a higher orientation and continuity of the LBL surface-supported metal-organic framework (SURMOF). Using an equimolar ratio of H₂/N₂, it is shown that selective separation of hydrogen over nitrogen occurs with a separation factor of 3.02 and 2.64 for the SURMOF and MOF membrane, respectively. To the best of our knowledge, this is the highest reported performance for a single-phase UiO-66-NH₂ membrane. For higher hydrogen concentrations, the separation factor decreases due to reduced interactions between pore walls and N₂ molecules.

Promising Isotope Effect in Pd77Ag23 for Hydrogen Separation

Pd–Ag alloys are largely used as hydrogen separation membranes and, as a consequence, the Pd–Ag–H system has been intensively studied. On the contrary, fewer information is available for the Pd–Ag–D system; thus, the aim of this work is to improve the knowledge of the isotope effect on the commercial Pd77Ag23 alloy, especially for temperature above 200 °C. In particular, deuterium absorption measurements are carried out in the Pd77Ag23 alloy in the temperature range between 79 and 400 °C and in the pressure range between 10−2 and 16 bar. In this exploited pressure (p) and composition (c) range, above 300 °C the pc isotherms display the typical shape of materials where only a solid solution of deuterium is present while at lower temperatures these curves seem to be better described by the coexistence of a solid solution and a deuteride in a large composition range. The obtained results are compared and discussed with the ones previously measured with the lightest hydrogen isotope. Such a comparison shows that the Pd77Ag23 alloy exhibits a clear inverse isotope effect, as the equilibrium pressure of the Pd–Ag–D system is higher than in Pd–Ag–H by a factor of ≈2 and the solubility of deuterium is about one half of that of hydrogen. In addition, the absorption measurements were used to assess the deuteration enthalpy that below 300 °C is ΔHdeut = 31.9 ± 0.3 kJ/mol, while for temperatures higher than 300 °C, ΔHdeut increases to 43 ± 1 kJ/mol. Additionally, in this case a comparison with the lighter isotope is given and both deuteration enthalpy values result lower than those reported for hydrogenation. The results described in this paper are of practical interest for applications operating above 200 °C, such as membranes or packing column, in which Pd77Ag23 has to interact with a gas stream containing both hydrogen isotopes.

Catalytic Membrane Reactors: The Industrial Applications Perspective

Catalytic membrane reactors have been widely used in different production industries around the world. Applying a catalytic membrane reactor (CMR) reduces waste generation from a cleaner process perspective and reduces energy consumption in line with the process intensification strategy. A CMR combines a chemical or biochemical reaction with a membrane separation process in a single unit by improving the performance of the process in terms of conversion and selectivity. The core of the CMR is the membrane which can be polymeric or inorganic depending on the operating conditions of the catalytic process. Besides, the membrane can be inert or catalytically active. The number of studies devoted to applying CMR with higher membrane area per unit volume in multi-phase reactions remains very limited for both catalytic polymeric and inorganic membranes. The various bio-based catalytic membrane system is also used in a different commercial application. The opportunities and advantages offered by applying catalytic membrane reactors to multi-phase systems need to be further explored. In this review, the preparation and the application of inorganic membrane reactors in the different catalytic processes as water gas shift (WGS), Fisher Tropsch synthesis (FTS), selective CO oxidation (CO SeLox), and so on, have been discussed.

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.

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.

Hydrogen Selective SiCH Inorganic-Organic Hybrid/γ-Al2O3 Composite Membranes

Solar hydrogen production via the photoelectrochemical water-splitting reaction is attractive as one of the environmental-friendly approaches for producing H₂. Since the reaction simultaneously generates H₂ and O₂, this method requires immediate H₂ recovery from the syngas including O₂ under high-humidity conditions around 50 °C. In this study, a supported mesoporous γ-Al₂O₃ membrane was modified with allyl-hydrido-polycarbosilane as a preceramic polymer and subsequently heat-treated in Ar to deliver a ternary SiCH organic–inorganic hybrid/γ-Al₂O₃ composite membrane. Relations between the polymer/hybrid conversion temperature, hydrophobicity, and H₂ affinity of the polymer-derived SiCH hybrids were studied to functionalize the composite membranes as H₂-selective under saturated water vapor partial pressure at 50 °C. As a result, the composite membranes synthesized at temperatures as low as 300–500 °C showed a H₂ permeance of 1.0–4.3 × 10⁻⁷ mol m⁻² s⁻¹ Pa⁻¹ with a H₂/N₂ selectivity of 6.0–11.3 under a mixed H₂-N₂ (2:1) feed gas flow. Further modification by the 120 °C-melt impregnation of low molecular weight polycarbosilane successfully improved the H₂-permselectivity of the 500 °C-synthesized composite membrane by maintaining the H₂ permeance combined with improved H₂/N₂ selectivity as 3.5 × 10⁻⁷ mol m⁻² s⁻¹ Pa⁻¹ with 36. These results revealed a great potential of the polymer-derived SiCH hybrids as novel hydrophobic membranes for purification of solar hydrogen.

Functional catalytic membrane development: A review of catalyst coating techniques

Catalytic membranes combine catalytic activity with conventional filtration membranes, thus enabling diverse attractive benefits into the conventional membrane filtration processes, such as easy catalyst reuse, antifouling, anti-microbial, and enhancing process efficiency. Up to date, tremendous progresses have been made on functional catalytic membrane preparation and applications, which significantly advances the competitiveness of membrane technologies in process industries. The present article provides a critical and holistic overview of the current state of knowledge on existing catalyst coating techniques for functional catalytic membrane development. Based on coating mechanisms, the techniques are generally categorized into physical and chemical surface coating routes. For each technique, we first introduce fundamental principle, followed by a critical discussion of their applications with representative case studies. Advantages and drawbacks are also emphasized for different surface coating technologies. Finally, future perspectives are highlighted to provide deep insights into their future developments.

3D-MID Technology for Surface Modification of Polymer-Based Composites: A Comprehensive Review

The three-dimensional molded interconnected device (3D-MID) has received considerable attention because of the growing demand for greater functionality and miniaturization of electronic parts. Polymer based composite are the primary choice to be used as substrate. These materials enable flexibility in production from macro to micro-MID products, high fracture toughness when subjected to mechanical loading, and they are lightweight. This survey proposes a detailed review of different types of 3D-MID modules, also presents the requirement criteria for manufacture a polymer substrate and the main surface modification techniques used to enhance the polymer substrate. The findings presented here allow to fundamentally understand the concept of 3D-MID, which can be used to manufacture a novel polymer composite substrate.

Membrane materials for energy production and storage

Ion exchange membranes are widely used in chemical power sources, including fuel cells, redox batteries, reverse electrodialysis devices and lithium-ion batteries. The general requirements for them are high ionic conductivity and selectivity of transport processes. Heterogeneous membranes are much cheaper but less selective due to the secondary porosity with large pore size. The composition of grafted membranes is almost identical to heterogeneous ones. But they are more selective due to the lack of secondary porosity. The conductivity of ion exchange membranes can be improved by their modification via nanoparticle incorporation. Hybrid membranes exhibit suppressed transport of co-ions and fuel gases. Highly selective composite membranes can be synthesized by incorporating nanoparticles with modified surface. Furthermore, the increase in the conductivity of hybrid membranes at low humidity is a significant advantage for fuel cell application. Proton-conducting membranes in the lithium form intercalated with aprotic solvents can be used in lithium-ion batteries and make them more safe. In this review, we summarize recent progress in the synthesis, and modification and transport properties of ion exchange membranes, their transport properties, methods of preparation and modification. Their application in fuel cells, reverse electrodialysis devices and lithium-ion batteries is also reviewed.

Ultra-Pure Hydrogen via Co-Valorization of Olive Mill Wastewater and Bioethanol in Pd-Membrane Reactors

Olive mill wastewater (OMW) presents high environmental impact due to the fact of its elevated organic load and toxicity, especially in Mediterranean countries. Its valorization for simultaneous pollutants degradation and green energy production is receiving great attention, mainly via steam reforming for hydrogen generation. Following previous works, the present research goes into detail about OMW valorization, particularly investigating for the first time the potential benefits of OMW–bioethanol mixtures co-reforming for ultra-pure hydrogen production in Pd-membrane reactors. In this manner, the typical large dilution of OMW and, hence, excess water can be used as a reactant for obtaining additional hydrogen from ethanol. Fresh OMW was previously conditioned by filtration and distillation processes, analyzing later the effect of pressure (1–5 bar), oxidizing conditions (N2 or air as carrier gas), gas hourly space velocity (150–1500 h−1), and alcohol concentration on the co-reforming process (5–10% v/v). In all cases, the exploitation of OMW as a source of environmentally friendly hydrogen was demonstrated, obtaining up to 30 NmL·min−1 of pure H2 at the most favorable experimental conditions. In the membrane reactor, higher pressures up to 5 bar promoted both total H2 production and pure H2 recovery due to the increase in the permeate flux despite the negative effect on reforming thermodynamics. The increase of ethanol concentration also provoked a positive effect, although not in a proportional relation. Thus, a greater effect was obtained for the increase from 5% to 7.5% v/v in comparison to the additional improvement up to 10% v/v. On the contrary, the use of oxidative conditions slightly decreased the hydrogen production rate, while the effect of gas hourly space velocity needs to be carefully analyzed due to the contrary effect on potential total H2 generation and pure H2 recovery.

Pd-Based Membranes: Overview and Perspectives

Palladium (Pd)-based membranes have received a lot of attention from both academia and industry thanks to their ability to selectively separate hydrogen from gas streams. Integration of such membranes with appropriate catalysts in membrane reactors allows for hydrogen production with CO₂ capture that can be applied in smaller bioenergy or combined heat and power (CHP) plants, as well as in large-scale power plants. Pd-based membranes are, therefore, regarded as a Key Enabling Technology (KET) to facilitate the transition towards a knowledge-based, low carbon and resource-efficient economy. This Special Issue of the journal Membranes on “Pd-based Membranes: Overview and Perspectives” contains nine peer-reviewed articles. Topics include manufacturing techniques, understanding of material phenomena, module and reactor design, novel applications, and demonstration efforts and industrial exploitation.

Solar Energy Assisted Membrane Reactor for Hydrogen Production

Pd-based membrane reactors are strongly recognized as an effective way to boost H2 yield and natural gas (NG) conversion at low temperatures, compared to conventional steam reforming plants for hydrogen production, thereby representing a potential solution to reduce the energy penalty of such a process, while keeping the lower CO2 emissions. On the other hand, the exploitation of solar energy coupled with a membrane steam reformer can further reduce the environmental impact of these systems. On this basis, the paper deals with the design activities and experimentation carried out at a pilot level in an integrated prototype where structured catalysts and Pd-based membranes are arranged together and thermally supported by solar-heated molten salts for steam reforming reaction

Progress in Modeling of Silica-Based Membranes and Membrane Reactors for Hydrogen Production and Purification

Hydrogen is seen as the new energy carrier for sustainable energy systems of the future. Meanwhile, proton exchange membrane fuel cell (PEMFC) stacks are considered the most promising alternative to the internal combustion engines for a number of transportation applications. Nevertheless, PEMFCs need high-grade hydrogen, which is difficultly stored and transported. To solve these issues, generating hydrogen using membrane reactor (MR) systems has gained great attention. In recent years, the role of silica membranes and MRs for hydrogen production and separation attracted particular interest, and a consistent literature is addressed in this field. Although most of the scientific publications focus on silica MRs from an experimental point of view, this review describes the progress done in the last two decades in terms of the theoretical approach to simulate silica MR performances in the field of hydrogen generation. Furthermore, future trends and current challenges about silica membrane and MR applications are also discussed.

Tilted Fiber Bragg Grating Sensor Using Chemical Plating of a Palladium Membrane for the Detection of Hydrogen Leakage

A tilted fiber Bragg grating (TFBG) hydrogen sensor coated with a palladium (Pd) membrane by the electroless plating method is proposed in this paper. A uniform layer of Pd metal is fabricated in aqueous solutions by the chemical coating method, which is used as the sensitive element to detect the change of the surrounding refractive index (SRI) caused by hydrogen absorption. The change in SRI causes an unsynchronized change of the cladding modes and the Bragg peak in the TFBG transmission spectrum, thereby eliminating the cross-sensitivity due to membrane expansion and is able to simultaneously monitor the presence of cracks in the pipe, as well as the hydrogen leakage. By subtracting the wavelength shift caused by fiber expansion, the change of SRI, i.e., the information from the H₂ level, can be separately obtained. The drifted wavelength is measured for the H₂ concentration below the hydrogen explosion limit between 1% and 4%. The chemical-based coating has the advantages of a low cost, a simple operation, and being suitable for coating on long fiber structures. The proposed sensor is able to detect the H₂ signal in 5 min at a 1% H₂ concentration. The proposed sensor is proved to be able to monitor the hydrogen level without the cross-sensitivity of temperature variation and expansion strains, so could be a good candidate for security applications in industry.

Advances in Methanol Production and Utilization, with Particular Emphasis toward Hydrogen Generation via Membrane Reactor Technology

Methanol is currently considered one of the most useful chemical products and is a promising building block for obtaining more complex chemical compounds, such as acetic acid, methyl tertiary butyl ether, dimethyl ether, methylamine, etc. Methanol is the simplest alcohol, appearing as a colorless liquid and with a distinctive smell, and can be produced by converting CO₂ and H₂, with the further benefit of significantly reducing CO₂ emissions in the atmosphere. Indeed, methanol synthesis currently represents the second largest source of hydrogen consumption after ammonia production. Furthermore, a wide range of literature is focused on methanol utilization as a convenient energy carrier for hydrogen production via steam and autothermal reforming, partial oxidation, methanol decomposition, or methanol⁻water electrolysis reactions. Last but not least, methanol supply for direct methanol fuel cells is a well-established technology for power production. The aim of this work is to propose an overview on the commonly used feedstocks (natural gas, CO₂, or char/biomass) and methanol production processes (from BASF-Badische Anilin und Soda Fabrik, to ICI-Imperial Chemical Industries process), as well as on membrane reactor technology utilization for generating high grade hydrogen from the catalytic conversion of methanol, reviewing the most updated state of the art in this field.

Dry Reforming of Methane in a Pd-Ag Membrane Reactor: Thermodynamic and Experimental Analysis

The present work is a study of CO2 Reforming of Methane (DRM) carried out in a catalytic Pd-based membrane reactor. A detailed thermodynamic analysis is carried out, calculating the chemical equilibrium parameters in two different cases: (a) DRM along with the Reverse Water Gas Shift (RWGS) reaction and (b) DRM along with both RWGS and the Boudouard Reaction (BR). The performance of membrane reactor is then experimentally analyzed in terms of methane conversion, hydrogen recovery and H2/CO reaction selectivity by varying feed pressure and CO2/CH4 feed molar ratio and 500 °C and GHSV = 100 h−1. Among the obtained results, a CH4 conversion of about 26% and a H2 recovery of 47% are achieved at low feed pressures, exceeding the traditional reactor equilibrium conversion. This effect can be attributed to the favorable thermodynamics coupled to the hydrogen permeation through the membrane. This study further demonstrates the general effectiveness of membrane-integrated reaction processes, which makes the production of syngas more efficient and performing, providing important environmental benefits.

Hydrogen Diffusion and Trapping in α-Iron: The Role of Quantum and Anharmonic Fluctuations

We investigate the thermodynamics and kinetics of a hydrogen interstitial in magnetic α-iron, taking account of the quantum fluctuations of the proton as well as the anharmonicities of lattice vibrations and hydrogen hopping. We show that the diffusivity of hydrogen in the lattice of bcc iron deviates strongly from an Arrhenius behavior at and below room temperature. We compare a quantum transition state theory to explicit ring polymer molecular dynamics in the calculation of diffusivity. We then address the trapping of hydrogen by a vacancy as a prototype lattice defect. By a sequence of steps in a thought experiment, each involving a thermodynamic integration, we are able to separate out the binding free energy of a proton to a defect into harmonic and anharmonic, and classical and quantum contributions. We find that about 30% of a typical binding free energy of hydrogen to a lattice defect in iron is accounted for by finite temperature effects, and about half of these arise from quantum proton fluctuations. This has huge implications for the comparison between thermal desorption and permeation experiments and standard electronic structure theory. The implications are even greater for the interpretation of muon spin resonance experiments.