Multilayer Tape Casting of Water-Gas-Shift Membranes for H2 Separation

In the production of hydrogen, current materials and systems used as hydrogen separators for water-gas-shift reactors present two major problems, namely, cost and robustness. These issues are being addressed through the use of palladium alloys, various ceramic substrates, and nanomaterials; however, these new materials still have manufacturing drawbacks due to the fact that they are manufactured via the costly Pressure Vapor Desposition (PVD) and Chemical Vapor Deposition (CVD) processing of alloys onto a substrate. This project will investigate the production and manufacture of a robust two-phase interconnecting hydrogen separator, wherein a ceramic substrate is used to reduce the degradation of a hydrogen purification membrane made of a low-content palladium-copper alloy. The entire system can be produced in bulk using robust tape casting technology, originally developed for powder ceramics, and battery technology, in order to reduce the cost of the membrane. Commercial Applications and other Benefits as described by the awardee: If successful, the technology should drastically alter the manufacture of hydrogen separator membranes. Costs would be lowered dramatically, not only by reducing raw material costs but also by reducing manufacturing costs. The proposed system should reduce the cost of a hydrogen separation membrane by a factor of 20 compared to the pure Pd membranes that are used currently, and should be more robust at the same time.