Cost Effective Ulta-Thin Palladium Based Membrane for Hydrogen Separation and Purification

78108S Hydrogen separation and purification is an enabling technology of the DOE FutureGen Program. The successful development of cost-effective hydrogen separation technology is a key element to separation/sequestration of carbon dioxide and delivery of high purity hydrogen for chemical processes or fuel cell applications. Current hydrogen membrane separation technology is costly and not oriented toward large-scale manufacturing. Current processes to produce very thin metal films, offering enhanced hydrogen permeability and lower cost, have proven to be problematic. Metal deposition techniques are expensive and do not achieve uniform thickness. Physical rolling can yield films of uniform thickness, but below 25 micrometers they have little structural integrity, are difficult to handle, and prone to formation of cracks and pinholes. This project will adapt metal cladding technology to produce a combined membrane and support structure of superior performance and structural integrity that has significantly lower material and manufacturing costs. Phase I addresses the adaptation and further development of rolling-bonding technology to simultaneously form and clad ultra-thin metal foils to porous metal support structures. The validity of the approach will be established by using a test stand to measure hydrogen flux and electron microscopy to view the physical structure. Phase II will focus on larger scale manufacture of the membranes and their integration into an assembly sufficient to process large volumes of coal-derived syngas. Commercial Applications and other Benefits as described by the awardee: The technology should have significant ramifications in achieving DOE performance and cost targets for its Hydrogen, Fuel Cells, and Infrastructure programs. These targets represent the signposts that define the transition to the Hydrogen Economy.