" This work investigated the long-term stability of sulfur tolerant Pd/Cu alloy membranes for hydrogen separation by performing characterizations lasting several thousand hours in H2, He and H2S/H2 atmospheres ranging in concentration from 0.2 – 50 ppm and temperatures ranging from 250 - 500ºC. Two methods were used for fabricating the Pd/Cu membranes so that the sulfur tolerant fcc alloy would remain on the surface and minimize the decrease in hydrogen permeance inherent with fcc Pd/Cu alloys. The first method consisted of annealing a Pd/Cu bi-layer at high-temperatures and the second consisted of depositing a Pd/Cu/Pd tri-layer with an ultra-thin surface alloy. High temperature X-ray diffraction (HT-XRD) was employed to study the kinetics of the annealing process and atomic adsorption spectroscopy (AAS) was used to investigate the kinetics of the Cu deposition and Pd displacement of Cu. Upon the introduction of H2S, the permeance decrease observed was dependent upon the H2S feed concentration, and not the time of poisoning. However, after the recovery in pure H2 there was a portion of the permeance which could not be recovered due to adsorbed sulfur blocking H2 adsorption sites. The amount of recoverable permeance was dependent on the time of exposure to H2S and reached a limiting value which decreased with temperature. X-ray photoemission spectroscopy (XPS) was used to investigate poisoned samples and it was observed that the permeance not recovered at a given temperature in H2 was caused mostly by Cu sulfides. Both bi-layer and tri-layer membranes had hydrogen permeances which were higher than homogeneous Pd/Cu membranes of the same surface concentration. However, the tri-layer membranes performed as well as Pd membranes thus eliminating the disadvantage of alloying Pd with Cu without sacrificing sulfur tolerance. "

This work describes a novel technique to prepare ultra-thin composite Pd-porous metal membranes for H2 separation. This novel technique consists of the gradual smoothing of the Porous Metal (PM) support's surface with several layers of pre-activated alumina particles of different sizes. The deposition of coarse, fine and ultra-fine alumina particles resulted in the narrowing of the PM' surface pore size distribution. The excellent surface smoothness achieved after the grading of the PM 's surface support allowed for the preparation of gas tight Pd layers as thin as 5.6?m. The Pd layers were extremely uniform due to the presence of the grade layer and strongly attached to the support. Composite Pd membranes prepared on graded supports showed H2 permeance as high as 50 m3/(m2 h bar0.5) at 500ºC and ideal selectivities (H2/He) as high as 27000. Moreover, the H2 permeance and ideal selectivity were stable over 1100 hours at 500ºC in H2 atmosphere. Composite Pd-Cu membranes showed H2 permeance as high as 30 m3/(m2 h bar0.5) at 450ºC and ideal selectivities (H2/He) as high as 900. The H2 permeance and ideal selectivity of Pd-Cu membranes were stable over 500 hours at 450ºC in H2 atmosphere. The outstanding long-term H2 permeance and ideal selectivity stability of all composite Pd and Pd-Cu membranes represented a breakthrough in composite Pd membrane synthesis. The thermal stresses arising from the mismatch in the coefficient of thermal expansion between the Pd film and the support were determined by means of x-ray diffraction. The results indicated that the release of stresses began to occur at temperatures close to 400ºC. Also, the release of stresses took place with a visible sintering of Pd clusters within the thin Pd film. The stresses due to the absorption of H2 were also studied and modeled. It was estimated that the maximum compressive stress under which these composite Pd membranes were characterized was equal to 260 MPa.

This thesis describes a new technique for the preparation of ultrathin Pd based membranes supported on a hollow-fiber α-alumina substrate for H₂ separation. The effectiveness of the membranes is demonstrated in the ethanol steam reforming (EtOH SR) reaction in a membrane reactor (MR) for H₂ production. The membrane preparation technique uses an electric-field to uniformly deposit Pd nanoparticle seeds on a substrate followed by deposition of Pd or Pd-Cu layers on the activated surface by electroless plating (ELP). The well distributed Pd nanoparticles allow for enhanced bonding between the selective layer and the substrate and the formation of gas tight and thermally stable Pd or Pd-Cu layers as thin as 1 µm, which is a record in the field. The best Pd membrane showed H₂ permeance as high as 5.0 × 10⁶ mol m²s⁻¹Pa⁻¹ and stable H²/N₂ selectivity of 9000 - 7000 at 733 K for 5 days. The Pd-Cu alloy membrane showed H₂ permeance of 2.5 × 10⁶ mol m⁻²s⁻¹Pa⁻¹ and H₂/N₂ selectivity of 970 at the same conditions. The reaction studies were carried out with a Co-Na/ZnO catalyst both in a packed bed reactor (PBR) and in a MR equipped with the Pd or Pd-Cu membrane to evaluate the benefits of employing membranes. For all studies, ethanol conversion and hydrogen product yields were significantly higher in the MRs compared to the PBR. Average ethanol conversion enhancement and hydrogen molar flow enhancement were measured to be 12 % and 11 % in the Pd MR and 22 % and 19 % in the Pd-Cu MR, respectively. These enhancements of the conversion and product yield can be attributed to the shift in reaction equilibria by continuous hydrogen removal by the Pd based membranes. The comparative low enhancement in the Pd MR was found to be the result of significant contamination of Pd layer by CO or carbon compounds deposition during the reaction. A one-dimensional modeling of the MR and the PBR was conducted using identical conditions and their performances were compared with the values obtained from the experimental study. The model was developed using a simplified power law and the predicted values matched experimental data with only minor deviations indicating that the model was capturing the essential physicochemical behavior of the system. Enhancements of ethanol conversion and hydrogen yield were observed to increase with rise in space velocity (SV), which could be explained by the increase in H₂ flux through the membranes with SV in the MRs. / Ph. D.