Preparation of “pore-fill” type Pd–YSZ–γ-Al2O3 composite membrane supported on α-Al2O3 tube for hydrogen separation

Mesoporous YSZ–γ-Al₂O₃ membranes were coated on α-Al₂O₃ (Ø2 mm) tube by dipping the α-Al₂O₃ support tube into mixed sol consists of nano-size YSZ and bohemite particles followed by drying and calcination at 600 °C. Addition of bohemite in YSZ sol helped a good adhesion and uniform coating of the membrane film onto α-Al₂O₃ support. The quality of the mesoporous YSZ–γ-Al₂O₃ membranes was evaluated by the gas permeability experiments. The number of defects was minimized when the γ-Al₂O₃ content became more than 40%. Addition of γ-Al₂O₃ inhibited the crystal growth of YSZ, sintering shrinkage and distortion stress. Increase of calcination temperature and time results in the increase of pore size and N₂ permeance. A hydrogen perm-selective membrane was prepared by filling palladium into the nano-pores of YSZ–γ-Al₂O₃ layer by vacuum-assisted electroless plating. Crystal growth of palladium was observed by thermal annealing of the membrane at 600 °C for 40 h. The Pd–YSZ–γ-Al₂O₃ composite membrane revealed improved thermal stability allowing long-term operation at elevated temperature (>500 °C). This has been attributed to the improved fracture toughness of YSZ–γ-Al₂O₃ layer and matching of thermal expansion coefficient between palladium and YSZ. Although fracture of the membrane did not occur, decline of H₂ flux was observed when the membrane was exposed in 600 °C. This has been attributed to the agglomeration of palladium particles by crystal growth and dense packing into the pore networks of YSZ–γ-Al₂O₃ by elevation of temperature.