Short Review on Porous Metal Membranes-Fabrication, Commercial Products, and Applications

A Review of the Recent Advances in Composite Membranes for Hydrogen Generation Technologies

Keeping global warming at 2 degrees and below as stated in the "Paris Climate Agreement" and minimizing emissions can only be achieved by establishing a hydrogen (H2) ecosystem. Therefore, H2 technologies stand out in terms of accomplishing zero net emissions. Although H2 is the most abundant element in the known universe, molecular H2 is very rare in nature and must be produced. In H2 production, reforming natural gas and renewable hydrogen processes using electrolyzers comes to the fore. The key to all these technologies is to enhance production speed, performance, and system lifetime. At this point, composite membranes used in both processes come to the fore. This review article summarizes composite membrane technologies used in methane, ethanol, and biomass steam reforming processes, proton exchange membranes, alkaline water electrolysis, and hybrid sulfur cycle. In addition to these common H2 production technologies at large quantities, the innovative systems developed with solar energy integration for H2 generation were linked to composite membrane utilization. This study aimed to draw attention to the importance of composite membranes in H2 production. It aims to prepare a guiding summary for those working on membranes by combining the latest and cutting-edge studies on this subject.

Femtosecond Laser Fabrication of Microporous Membranes for Biological Applications

The possibility of fabricating micrometric pore size membranes is gaining great interest in many applications, from studying cell signaling, to filtration. Currently, many technologies are reported to fabricate such microsystems, the choice of which depends strictly on the substrate material and on the final application. Here, we demonstrate the capability with a single femtosecond laser source and experimental setup to fabricate micromembranes both on polymeric and multilayer metallic substrate, without the need for moulds, mask, and complex facilities. In particular, the flexibility of laser drilling was exploited to obtain microfilters with pore size of 8 and 18 µm in diameter, on metallic and polymeric substrate, respectively, and controlled distribution. For evaluating the possibility to use such laser-fabricated membranes into biological assay, their biocompatibility has been investigated. To this aim, as a proof of concept, we tested the two materials into viability tests. The culture of mammalian cells on these microfabricated membranes were studied showing their compatibility with cells.

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.

Investigation of Duplex Brass Membranes with Metallography, Permeability and Treatments: Work-Hardening, Annealing and Quenching

This paper consists of the fabrication and investigation of metal membranes and the study of their behaviour and applications in gas separation processes. The scope is to produce and characterize the porous crystal structure of brass alloy (standardization: DIN 17660) membranes and measure their permeability with helium as a penetrant medium. Another part of this study is to alter the brass alloy’s structure throughout metallurgical treatments and investigate how the permeability is allied to the structure’s alteration. This work merges the knowledge and technology of inorganic porous materials science in metallurgy. The novelty of the current research resides in the process to alternate the brass alloy structure throughout metallurgical treatments and how it is allied to the permeability of the membrane, which is of interest to be investigated. The results of the research are analysed and compared conducting the final inferences. All metallurgical treatments resulted in low permeability values when compared to a non-treated specimen. Specifically, the drop in permeance ranged from 76 up to 99.56%. It is noted that consecutive treatments contributed to even further decreases.

Recent advances in gold nanoparticle-based lateral flow immunoassay for the detection of bacterial infection

Diagnosis of bacterial infections (BI) is becoming an increasingly difficult task in clinical practice due to their high prevalence and frequency, as well as the growth of antibiotic resistance worldwide. World Health Organization (WHO) reported antibiotic resistance is a major public health problem. BI becomes difficult or impossible to treat when the bacteria acquire immunity against antibiotics. Thus, there is a need for a quick and accurate technique to detect infection. Lateral flow immunoassay (LFIA) is an ideal technique for point-of-care testing of a disease or pathological changes inside the human body. In recent years, several LFIA based strips are being used for the detection of BI by targeting specific analytes which may range from the causative bacterium, whole-cell, DNA, or biomarker. Numerous nanoparticles like lipid-based nanoparticles, polymeric nanoparticles, and inorganic nanoparticles such as quantum dots, magnetic, ceramic, and metallic nanoparticles (copper, silver gold, iron) are widely being used in the advanced treatment of BI. Out of these gold nanoparticle (AuNPs), is being used for detection BI more effectively than other nanoparticles due to their surface functionalization, extraordinary chemical stability, biorecognition, and signal amplification properties and help to improve in conjugation with capture antibodies, and act as a color marker with unique optical properties on LFIA strips. Herein, a review that provides an overview of the principle of LFIA, how LFIA based strip is developed, and how it is helpful to detect a specific biomarker for bedside detection of the BI.

Charpy Impact Behavior of a Novel Stainless Steel Powder Wire Mesh Composite Porous Plate

A novel powder wire mesh composite porous plate (PWMCPP) was fabricated with 304 stainless steel powders and wire mesh as raw materials by vacuum solid-state sintering process using self-developed composite rolling mill of powder and wire mesh. The effects of different mesh volume fractions, mesh diameters, and sintering temperatures on the pore structure and Charpy impact properties of PWMCPPs were studied. The results show that PWMCPPs have different shapes and sizes of micropores. Impact toughness of PWMCPPs decreases with increasing wire mesh volume fraction, and increases first and then decreases with increasing wire mesh diameter, and increases with increasing sintering temperature. Among them, the sintering temperature has the most obvious effect on the impact toughness of PWMCPPs, when the sintering temperature increased from 1160 °C to 1360 °C, the impact toughness increased from 39.54 J/cm² to 72.95 J/cm², with an increased ratio of 84.5%. The tearing between layers, the fracture of the metallurgical junction, and the fracture of wire mesh are the main mechanisms of impact fractures of the novel PWMCPPs.

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.

Preparation and catalytic performance of active metal sintered membrane reactor anchored with Pt atoms

In the chemical industry, reactors are typically designed and filled with supported catalyst particles. However, the intrinsic problems associated with the internal/external diffusion effect and catalyst separation/loss in these traditional reactors can be very challenging to mitigate. To address these issues, herein, an active metal sintered membrane reactor anchored with Pt atoms was successfully developed, and applied into continuous, liquid-phase, hydrogenation processes. The catalyzing reactions transpired on the active sites that were fastened onto the surface of the reactor's microchannels. As a result, the mass transfer at the gas-liquid-solid three-phase was greatly enhanced, and an incredibly high reaction efficiency was obtained. The novel, active reactor demonstrated a superior catalytic performance and stability to nitrobenzene (NB) hydrogenation at 120 °C and 0.5 MPa H2, which enabled an aniline (ANI) yield of 19.28 molANI h-1 L-1. This work opens a new window for the design of high-performance gas-liquid-solid reactor toward multiphase catalytic reactions.

Nanoporous metal-polymer composite membranes for organics separations and catalysis

Metallic thin-film composite membranes are produced by sputtering metal films onto commercial polymer membranes. The separations capability of the membrane substrate is enhanced with the addition of a 10 nm Ta film. The addition of a tantalum layer decreases the molecular weight cutoff of the membrane from 70 kDa dextran (19 nm) to below 5 kDa (6 nm). Water flux drops from 168 LMH/bar (LMH: liters/meters2/hour) (polymer support) to 8.8 LMH/bar (Ta composite). A nanoporous layer is also added to the surface through Mg/Pd film deposition and dealloying. The resulting nanoporous Pd is a promising catalyst with a ligament size of 4.1 ± 0.9 nm. The composite membrane's ability to treat water contaminated with chlorinated organic compounds (COCs) is determined. When pressurized with hydrogen gas, the nanoporous Pd composite removes over 70% of PCB-1, a model COC, with one pass. These nanostructured films can be incorporated onto membrane supports enabling diverse reactions and separations.

High-Performance Polymer Foams by Thermally Induced Phase Separation

Macroporous, low-density polyetheretherketone, polyetherketoneketone, and polyetherimide foams are produced using a high-temperature, thermally induced phase separation method. A high-boiling-point solvent, which is suitable to dissolve at least 20 wt% of these high-performance polymers at temperatures above 250 °C, is identified. The foam morphology is controlled by the cooling procedure. The resulting polymer foams have porosities close to 80% with surface areas up to 140 m² g^-1 and elastic moduli up to 97 MPa.

Effect of Relative Density on Compressive Load Response of Crumpled Aluminium Foil Mesh

In recent years, a large number of metal foams and porous metals have been developed. Due to the high cost of these materials alternative manufacturing methods for cellular metallic materials are being explored. Crumpled metallic foil meshes, manufactured via die compression techniques, are evolving as a potential alternative method. However, the non-availability of sufficient data on their load response is limiting their uptake. Uniaxial compressive load response of crumpled aluminium foil meshes (CAFMs) of varying densities, forged by open and closed die compression, are studied. A 0.05 mm thick aluminium sheet mesh, manufactured by the expanded metal process is used. X-ray computed micro-tomography is employed to image the CAFM's internal cellular structure. The stress-strain relation demonstrates that the CAFMs produce identical load response profile irrespective of their relative density. Power law functions E R = 17110 ρ r 3.6547 and σ Y , E = 53.092 ρ r 2.2249 define the relationships between real Young's Modulus E R and effective yield strength, σ Y , E . The study provides new knowledge on the effect of relative density on the compressive properties of CAFMs which have applications across lightweight structural design.

Techno-Economic Assessment in a Fluidized Bed Membrane Reactor for Small-Scale H2 Production: Effect of Membrane Support Thickness

This paper investigates the influence of the support material and its thickness on the hydrogen flux in Palladium membranes in the presence of sweep gas in fluidized bed membrane reactors. The analysis is performed considering both ceramic and metallic supports with different properties. In general, ceramic supports are cheaper but suffer sealing problems, while metallic ones are more expensive but with much less sealing problems. Firstly, a preliminary analysis is performed to assess the impact of the support in the permeation flux, which shows that the membrane permeance can be halved when the H₂ diffusion through the support is considered. The most relevant parameter which affects the permeation is the porosity over tortuosity ratio of the porous support. Afterward, the different supports are compared from an economic point of view when applied to a membrane reactor designed for 100 kg/day of hydrogen, using biogas as feedstock. The stainless steel supports have lower impact on the hydrogen permeation so the required membrane surface area is 2.6 m² compared to 3.6 m² of the best ceramic support. This ends up as 5.6 €/kg H_2@20bar and 6.6 €/kg H_2@700bar for the best stainless steel support, which is 3% lower than the price calculated for the best ceramic support.

Preparation and Properties of Titanium Obtained by Spark Plasma Sintering of a Ti Powder⁻Fiber Mixture

Porous titanium is a functional structural material with certain porosity, which is prepared from titanium powder and titanium fiber. In order to study the porosity, phase structure, microstructure, sintering mechanism and mechanical properties of porous titanium obtained by spark plasma sintering of a Ti powder⁻fiber mixture at different sintering temperatures, a spherical titanium powder (D50 of 160 μm) was prepared via plasma rotating electrode processing, and titanium fiber (average wire diameter of fiber of 110 μm) was prepared by drawing, and they were mixed as raw materials according to different mass ratios. Porous titanium with a fiber⁻powder composite porous structure was prepared by spark plasma sintering at sintering temperatures of 800 °C, 900 °C and 1000 °C under a sintering pressure of 20 MPa. The results showed that there were no new phases occurring in porous titanium with porosity of 1.24⁻24.6% after sintering. Titanium fiber and titanium powder were sintered using powder/powder, powder/fiber and fiber/fiber regimes to form composite pore structures. The mass transfer mechanism of the sintered neck was a diffusion-dominated material migration mechanism during sintering. At higher sintering temperatures, the grain size was larger, and the fiber (800 °C; 10⁻20 μm) was finer than the powder (800 °C; 10⁻92 μm). The stress⁻strain curve of porous titanium showed no obvious yield point, and the compressive strength was higher at higher sintering temperatures. The results of this paper can provide data reference for the preparation of porous titanium obtained by spark plasma sintering of a Ti powder⁻fiber mixture.