Worcester Polytechnic Institute

Erik E Engwall

Yi Hua Ma

Ivan P Mardilovich

The present invention relates to a method for fabricating a composite gas separation module and to gas separation modules formed by the method. In one embodiment, the method for fabricating a composite gas separation module includes depositing a first material on a porous substrate, thereby forming a coated substrate. The coated substrate is abraded, thereby forming a polished substrate. A second material is then deposited on the polished substrate. The first material, the second material, or both the first material and the second material can include a gas-selective material such as a hydrogen-selective metal, e.g., palladium, or an alloy thereof. In one embodiment, the method includes the step of forming a dense gas-selective membrane over the porous substrate. The present invention also relates to a method for selectively separating hydrogen gas from a hydrogen gas-containing gaseous stream.

Method for fabricating composite gas separation modules

A composite gas separation module includes a porous metal substrate; an intermediate layer that includes a powder having a Tamman temperature higher than the Tamman temperature of the porous metal substrate and wherein the intermediate layer overlies the porous metal substrate; and a dense hydrogen-selective membrane, wherein the dense hydrogen-selective membrane overlies the intermediate layer. In another embodiment, a composite gas separation module includes a porous metal substrate; an intermediate powder layer; and a dense gas-selective membrane, wherein the dense gas-selective membrane overlies the intermediate powder layer.

Composite gas separation modules having high Tamman temperature intermediate layers

The present invention relates to a composite gas separation module and to methods for fabricating a composite gas separation module. The present invention also relates to methods for selectively separating hydrogen gas from a hydrogen gas-containing gaseous stream. In one embodiment, the composite gas separation module includes a porous metal substrate; an intermediate porous metal layer, wherein the intermediate porous metal layer overlies the porous metal substrate; and a dense hydrogen-selective membrane, wherein the dense hydrogen-selective membrane overlies the intermediate porous metal layer. The intermediate porous metal layer can include palladium and a Group IB metal. For example, the intermediate porous metal layer can contain alternating layers of palladium and a Group IB metal.

Composite gas separation modules having intermediate porous metal layers

The present invention relates to a method for curing a defect in the fabrication of a composite gas separation module and to composite gas separation modules formed by a process that includes the method. The present invention also relates to a method for selectively separating hydrogen gas from a hydrogen gas-containing gaseous stream. The method for curing a defect in the fabrication of a composite gas separation module includes depositing a first material over a porous substrate, thereby forming a coated substrate, wherein the coated substrate contains at least one defect. Then, the coated substrate can be selectively surface activated proximate to the defect, thereby forming at least one selectively surface activated region of the coated substrate. A second material can be then preferentially deposited on the selectively surface activated region of the coated substrate, whereby the defect is cured.

Growing community of inventors

Worcester, MA, United States of America

Erik E Engwall