Development of selective Pd–Ag membranes on porous metal filters

Metallic supports with sufficient surface quality to achieve highly selective thin Pd–Ag membranes require specific pre-treatments, are not readily available on the market and are generally very expensive. To reduce costs, rough and large media grade Hastelloy X filters have been acquired and pre-treated via polishing and chemical etching. The loss in gas permeance given by the polishing treatment proved fully recovered after chemical etching. A method to fill the large pores of the filters via aspiration of α-Al2O3 water-powder suspension has been applied and characterized via imaging of the filled pores, inferential statistics, and capillary flow porometry measurements. The most suitable filler particle size for pore size distribution reduction has been identified as 18 μm, while a 5 μm filler proved optimal for further pore morphology improvement. The wide pore size distribution of the filters has thus been reduced up to 200 nm by filling with α-Al2O3 particles of decreasing size, similarly to the ceramic supports used for thin Pd–Ag membranes deposition. A boehmite based interdiffusion barrier has been deposited, achieving further surface roughness reduction. A highly H2 selective membrane has been obtained via simultaneous Pd–Ag plating on the pre-treated filter.