Multi-objective optimization of hydrogen production system based on the combined supercritical cycle and gas turbine plant

In this paper, considering the hydrogen production cycle coupled with the supercritical CO2 cycle, hydrogen is produced as a clean fuel along with power and heat production. Also, the world's need for clean energy doubles the solutions to achieve clean hydrogen energy. The investigated cycle has a supercritical CO2 cycle with a combustion chamber where enriched fuel is introduced. Combustion products produce work in the gas turbine, and further hydrogen separation is formed with the help of water gas shift reaction and hydrogen separation membrane. In the thermodynamic analysis, combustion chamber known as the most irreversible member of set, where the most exergy is lost. The energy and exergy efficiency for whole set are 64.82%, 52.46% respectively. Produced hydrogen mass flow rate calculated 46.8 kg/h. Also, multi-objective optimization based on genetic algorithm were done and the results were reported. All calculation and optimization method has been done in MATLAB software.

Collectable Single Pure-Pd Metal Membrane with High Strength and Flexibility Prepared through Electroplating for Hydrogen Purification

Among the various film preparation methods, electroplating is one of the simplest and most economical methods. However, it is challenging to collect a dense single Pd film through plating, owing to the accumulation of stress in the film during the process. Therefore, the characteristics of a single plated film have not been clearly identified, although pure Pd is widely used in metallic-hydrogen-purification membranes. In this study, stress concentration in film during preparation was reduced by optimizing the plating process, and a dense single flat film was successfully collected. No impurities were detected. Thus, a high-purity Pd film was prepared. Its surface texture was found to be significantly different from that of the rolled film, and several approximately 5 μm sized aggregates were observed on the surface. The plated film is reported to have mechanical properties superior to those of the rolled film, with twice the displacement and four times the breaking point strength. The hydrogen permeabilities of the plated film (5.4 × 10−9–1.1 × 10−8 mol·m−1·s−1·Pa−1/2 at 250–450 °C) were comparable to those of the rolled and reported films, indicating that the surface texture does not have a strong effect on hydrogen permeability. The results of this study promote the practical use of Pd-based membranes through electroplating.

Efficient methanol steam reforming over ZnCeZrOx: the unique role of cerium

Zn1Ce1Zr9Ox is a ternary solid solution with Zn and Ce doped into the lattice of ZrO2, which is more active and stable than the counterpart without cerium doping in steam reforming of methanol.

Pore flow-through catalytic membrane reactor for steam methane reforming: characterization and performance

A new reactor configuration with low Pd loadings allows good methane conversion results at low temperatures.

Gas-Transport Characteristics of PdCu–Nb–PdCu Membranes Modified with Nanostructured Palladium Coating

A method for obtaining composite gas-diffusion PdCu–Nb–PdCu membranes modified with a nanostructured crystalline coating was developed to increase the performance of Nb-based membranes. A modifying functional layer with a controlled size and composition was synthesized by electrochemical deposition, which made it possible to determine a certain geometric shape for palladium nanocrystallites. Developed PdCu–Nb–PdCu membranes have demonstrated flux values up to 0.232 mmol s⁻¹ m⁻² in the processes of diffusion purification of hydrogen at 400 °C. A very significant difference in the hydrogen fluxes through the modified and non-modified composite PdCu–Nb–PdCu membranes reached 1.73 times at the lower threshold temperature of 300 °C. Cu doping of protective layer did not affect the selective properties of the membranes, which was confirmed by the obtained high selectivity values up to 1323, and made it possible to reduce the noble metal content. The research data indicate that the modification of the membrane surface significantly accelerates the hydrogen transfer process at sufficiently low temperatures due to the acceleration of dissociative–associative processes on the surface. The reported approach demonstrates new possibilities for creating productive and cost-efficient membranes based on niobium.

Icosahedral cluster formation in Ni-based hydrogen separation amorphous membranes and the effect of hydrogenation-a first principles structural study

The demand for hydrogen is increasing due to commercialization of fuel cells. Palladium (Pd)-based crystalline membranes have been used for separation of hydrogen from a mixture of gases in coal-based power generation process. However, very high cost of Pd has prompted to explore inexpensive alternative alloys. Amorphous Ni-Nb-Zr alloy membranes are promising cheaper alternatives which exhibit comparable hydrogen permeability to Pd membranes at nominal temperature of ~ 400 °C. Constant exposure to high temperature and hydrogen pressure may lead to changes in the local atomic structure and possible devitrification of membrane. It is critical to understand short-range order of these membranes in order to improve their hydrogen permeability and durability. Icosahedral clusters are the building blocks of amorphous material and hydrogen is expected to interact with them in various different ways. The density functional theory-based molecular dynamics (DFT-MD) approach is the best suited approach to study the local atomic structures for (Ni_0.6Nb_0.4)₉₀Zr₁₀ and (Ni_0.6Nb_0.4)₇₀Zr₃₀ amorphous membranes with the help of nearest neighbor distances and icosahedral cluster analysis. It can help predict the behavior of the membrane under extreme operating conditions. Three types of icosahedra (so called Ni-centered, Zr-centered, and Nb-centered) were identified in six different compositions in these amorphous alloys. Evolution of these icosahedra with temperature and in the presence of hydrogen gave an insight into the local structure of the membrane. Zr plays an important role in the formation of icosahedra. Hydrogen atoms interact with the icosahedra in three different ways. It is observed that H atoms did not show tendency to enter Ni-centered icosahedra leading to easier hydrogen diffusion outside the icosahedra. Hence, the more the number of Ni-centered icosahedra, the better the permeation properties of the alloy.

Assessment of Sieverts Law Assumptions and 'n' Values in Palladium Membranes: Experimental and Theoretical Analyses

Palladium and palladium alloy membranes are superior materials for hydrogen purification, removal, or reaction processes. Sieverts’ Law suggests that the flux of hydrogen through such membranes is proportional to the difference between the feed and permeate side partial pressures, each raised to the 0.5 power (n = 0.5). Sieverts’ Law is widely applied in analyzing the steady state hydrogen permeation through Pd-based membranes, even in some cases where the assumptions made in deriving Sieverts’ Law do not apply. Often permeation data are fit to the model allowing the pressure exponent (n) to vary. This study experimentally assessed the validity of Sieverts’ Law as hydrogen was separated from other gases and theoretically modelled the effects of pressure and temperature on the assumptions and hence the accuracy of the 0.5-power law even with pure hydrogen feed. Hydrogen fluxes through Pd and Pd-Ag alloy foils from feed mixtures (5–83% helium in hydrogen; 473–573 K; with and without a sweep gas) were measured to study the effect of concentration polarization (CP) on hydrogen permeance and the applicability of Sieverts’ Law under such conditions. Concentration polarization was found to dominate hydrogen transport under some experimental conditions, particularly when feed concentrations of hydrogen were low. All mixture feed experiments showed deviation from Sieverts’ Law. For example, the hydrogen flux through Pd foil was found to be proportional to the partial pressure difference (n ≈ 1) rather than being proportional to the difference in the square root of the partial pressures (n = 0.5), as suggested by Sieverts’ Law, indicating the high degree of concentration polarization. A theoretical model accounting for Langmuir adsorption with temperature dependent adsorption equilibrium coefficient was made and used to assess the effect of varying feed pressure from 1–136 atm at fixed temperature, and of varying temperature from 298 to 1273 K at fixed pressure. Adsorption effects, which dominate at high pressure and at low temperature, result in pressure exponents (n) values less than 0.5. With better understanding of the transport steps, a qualitative analysis of literature (n) values of 0.5, 0.5 < n < 1, and n > 1, was conducted suggesting the role of each condition or step on the hydrogen transport based on the empirically fit exponent value.

Thin robust Pd membranes for low-temperature application

Thin tubular membranes (outer diameter, 2 mm, thickness < 4 mm) exhibits strong resistance against hydrogen embrittlement at temperatures below 100 °C due to reduced lattice strain gradients in cylindrical structures and lower residual stresses.

Microstructural Investigation and On-Site Repair of Thin Pd-Ag Alloy Membranes

Pd membranes act in an important role in H2 purification and H2 production in membrane reactors. Pd-Ag alloy membranes fabricated by consecutive electroless- and electroplating process on alumina tubes exhibited good stability under stringent heating/cooling cycles at a ramp rate of 10 K/min, imitating practical fast initiation or emergency shutdown conditions. Bilayer Pd-Ag membranes can form dense and uniform alloy after thermal treatment for 24 h at 823 K under H2 atmosphere, despite a porous structure due to the development of liquid-like properties above Tamman temperature to enforce the migrativity. On the contrary, alloying under N2 atmosphere resulted in a Pd-enriched layer. This led to a lower H2 flux but superior thermal stability compared to that alloying under H2 atmosphere. The trilayer approach of electroless-plated Pd, electro-polated Ag and electroless-plated Pd is not suitable to achieve homogeneous Pd-Ag alloys, which, on the other hand, presented the occurrence of a small gap between top Pd layer and middle Ag layer, probably due to insufficient wetting during plating process. An on-site repair treatment in analogous to MOCVD (Metal-organic Chemical Vapor Deposition) process was first proposed to extend the lifetime of Pd-Ag membrane, i.e., by vaporizing, and subsequent decomposition of Ag(OOCC2F5) powders to "preferentially" block the pinholes under vacuum and at working temperature of ca. 473-673 K, which effectively reduced the N2 flux by 57.4% compared to the initial value. The H2 flux, however, declined by 16.7% due to carbon deposition on the membrane surface, which requires further investigation. This approach shows some potential for on-site repair without disassembly or cooling to room temperature.

Flux-Reducing Tendency of Pd-Based Membranes Employed in Butane Dehydrogenation Processes

We report on the effect of butane and butylene on hydrogen permeation through thin state-of-the-art Pd-Ag alloy membranes. A wide range of operating conditions, such as temperature (200-450 °C) and H2/butylene (or butane) ratio (0.5-3), on the flux-reducing tendency were investigated. In addition, the behavior of membrane performance during prolonged exposure to butylene was evaluated. In the presence of butane, the flux-reducing tendency was found to be limited up to the maximum temperature investigated, 450 °C. Compared to butane, the flux-reducing tendency in the presence of butylene was severe. At 400 °C and 20% butylene, the flux decreases by ~85% after 3 h of exposure but depends on temperature and the H2/butylene ratio. In terms of operating temperature, an optimal performance was found at 250-300 °C with respect to obtaining the highest absolute hydrogen flux in the presence of butylene. At lower temperatures, the competitive adsorption of butylene over hydrogen accounts for a large initial flux penalty.

Effect of Hydrogen Separation on Coal Char Gasification with Subcritical Steam Using a Calcium-Based CO2 Sorbent

Coal char was gasified using subcritical steam with/without a CO₂ sorbent (CaO) and/or a hydrogen separation membrane (palladium-23% silver) in a batch/semibatch autoclave reactor to investigate the kinetics in terms of the effect of hydrogen separation at 590-650 °C and 1.9-2.4 MPa in order to support a hydrogen production process of the HyPr-RING method. CO₂ sorption by CaO affects the production rate of H₂ but scarcely affected the carbon conversion to gas. Hydrogen separation promotes the hydrogen production in spite of the absence of CO₂ sorption. The effect of hydrogen separation on hydrogen yield and carbon conversion was higher than that of CO₂ sorption. A higher gasification temperature increased the hydrogen yield and carbon conversion. Using a first-order reaction form in parallel, the gasification reaction mechanism was explained for the components of the volatile matter and char in coal char. A higher reaction temperature results in an increase of the values of any kinetic constant for subcritical steam gasification of Adaro coal char with/without CaO and/or a hydrogen separation membrane. CO₂ sorption promoted hydrogen production due to the tar from volatiles with the catalytic effects of CaO, whereas hydrogen separation promoted hydrogen production due to char.

Multiphase Methods in Organic Electrosynthesis

With water providing a highly favored solution environment for industrial processes (and in biological processes), it is interesting to develop water-based electrolysis processes for the synthesis and conversion of organic and biomass-based molecules. Molecules with low solubility in aqueous media can be dispersed/solubilized (i) by physical dispersion tools (e.g., milling, power ultrasound, or high-shear ultraturrax processing), (ii) in some cases by pressurization/supersaturation (e.g., for gases), (iii) by adding cosolvents or "carriers" such as chremophor EL, or (iv) by adding surfactants to generate micelles, microemulsions, and/or stabilized biphasic conditions. This Account examines and compares methodologies to bring the dispersed or multiphase system into contact with an electrode. Both the microscopic process based on individual particle impact and the overall electro-organic transformation are of interest. Distinct mechanistic cases for multiphase redox processes are considered. Most traditional electro-organic transformations are performed in homogeneous solution with reagents, products, electrolyte, and possibly mediators or redox catalysts all in the same (usually organic) solution phase. This may lead to challenges in the product separation step and in the reuse of solvents and electrolytes. When aqueous electrolyte media are used, reagents and products (or even the electrolyte) may be present as microdroplets or nanoparticles. Redox transformations then occur during interfacial "collisions" under multiphase conditions or within a reaction layer when a redox mediator is present. Benefits of this approach can be (i) the use of a highly conducting aqueous electrolyte, (ii) simple separation of products and reuse of the electrolyte, (iii) phase-transfer conditions in redox catalysis, (iv) new reaction pathways, and (v) improved sustainability. In some cases, a surface phase or phase boundary processes can lead to interesting changes in reaction pathways. Controlling the reaction zone within the multiphase redox system poses a challenge, and methods based on microchannel flow reactors have been developed to provide a higher degree of control. However, detrimental effects in microchannel systems are also observed, in particular for limited current densities (which can be very low in microchannel multiphase flow) or in the development of technical solutions for scale-up of multiphase redox transformations. This Account describes physical approaches (and reactor designs) to bring multiphase redox systems into effective contact with the electrode surface as well as cases of important electro-organic multiphase transformations. Mechanistic cases considered are "impacts" by microdroplets or particles at the electrode, effects of dissolved intermediates or redox mediators, and effects of dissolved redox catalysts. These mechanistic cases are discussed for important multiphase transformations for gaseous, liquid, and solid dispersed phases. Processes based on mesoporous membranes and hydrogen-permeable palladium membranes are discussed.

Low Concentration Response Hydrogen Sensors Based on Wheatstone Bridge

The PdNi film hydrogen sensors with Wheatstone bridge structure were designed and fabricated with the micro-electro-mechanical system (MEMS) technology. The integrated sensors consisted of four PdNi alloy film resistors. The internal two were shielded with silicon nitride film and used as reference resistors, while the others were used for hydrogen sensing. The PdNi alloy films and SiN films were deposited by magnetron sputtering. The morphology and microstructure of the PdNi films were characterized with X-ray diffraction (XRD). For efficient data acquisition, the output signal was converted from resistance to voltage. Hydrogen (H₂) sensing properties of PdNi film hydrogen sensors with Wheatstone bridge structure were investigated under different temperatures (30 °C, 50 °C and 70 °C) and H₂ concentrations (from 10 ppm to 0.4%). The hydrogen sensor demonstrated distinct response at different hydrogen concentrations and high repeatability in cycle testing under 0.4% H₂ concentration. Towards 10 ppm hydrogen, the PdNi film hydrogen sensor had evident and collectable output voltage of 600 μV.

Recent Developments in Compact Membrane Reactors with Hydrogen Separation

Hydrogen production and storage in small and medium scale, and chemical heat storage from renewable energy, are of great interest nowadays. Micro-membrane reactors for reforming of methane, as well as for the dehydrogenation of liquid organic hydrogen carriers (LOHCs), have been developed. The systems consist of stacked plates with integrated palladium (Pd) membranes. As an alternative to rolled and electroless plated (Pd) membranes, the development of a cost-effective method for the fabrication of Pd membranes by suspension plasma spraying is presented.

New Insight to the Effects of Heat Treatment in Air on the Permeation Properties of Thin Pd77%Ag23% Membranes

Sputtered Pd77%Ag23% membranes of thickness 2.2–8.5 µm were subjected to a three-step heat treatment in air (HTA) to investigate the relation between thickness and the reported beneficial effects of HTA on hydrogen transport. The permeability experiments were complimented by volumetric hydrogen sorption measurements and atomic force microscopy (AFM) imaging in order to relate the observed effects to changes in hydrogen solubility and/or structure. The results show that the HTA—essentially an oxidation-reduction cycle—mainly affects the thinner membranes, with the hydrogen flux increasing stepwise upon HTA of each membrane side. The hydrogen solubility is found to remain constant upon HTA, and the change must therefore be attributed to improved transport kinetics. The HTA procedure appears to shift the transition from the surface to bulk-limited transport to lower thickness, roughly from ~5 to ≤2.2 µm under the conditions applied here. Although the surface topography results indicate that HTA influences the surface roughness and increases the effective membrane surface area, this cannot be the sole explanation for the observed hydrogen flux increase. This is because considerable surface roughening occurs during hydrogen permeation (no HTA) as well, but not accompanied by the same hydrogen flux enhancement. The latter effect is particularly pronounced for thinner membranes, implying that the structural changes may be dependent on the magnitude of the hydrogen flux.

Perpendicular Magnetic Anisotropy and Hydrogenation-Induced Magnetic Change of Ta/Pd/CoFeMnSi/MgO/Pd Multilayers

The perpendicular magnetic anisotropy (PMA) has been achieved in Ta/Pd/CoFeMnSi (CFMS)/MgO/Pd film, in which the Heusler compound CoFeMnSi is one of the most promising candidates for spin gapless semiconductor (SGS). The strong PMA, with the effective anisotropy constant K_eff of 5.6 × 10⁵ erg/cm³ (5.6 × 10⁴ J/m³), can be observed in the Ta/Pd/CFMS (2.3 nm)/MgO (1.3 nm)/Pd films annealed at 300 °C. In addition, it was found that the magnetic properties of Ta/Pd/CFMS/MgO/Pd films are sensitive to hydrogen (H₂) under a weak magnetic field (< 30 Oe), whose residual magnetization (M_r) decreased from 123.15 to 30.75 emu/cm³ in the atmosphere with H₂ concentration of 5%.

"Modified" Liquid⁻Liquid Displacement Porometry and Its Applications in Pd-Based Composite Membranes

For H₂ separation by Pd-based composite membranes, the pore mouth size distribution of the porous support immediately affects the quality of the deposited layer, including continuity and defect/pinhole formation. However, there is a lack of convenient and effective methods for characterization of pore mouth size of porous supports as well as of defect distribution of dense Pd-based composite membranes. Here we introduce a novel method by modifying conventional liquid⁻liquid displacement porometry. When the pore tunnels are filled with Liquid B and the outer surface is occupied by Liquid A, the reopening of the pore mouth depends on the pressure of Liquid B and the interfacial tension at the position of the pore mouth, from which the pore mouth size can be determined according to the Young⁻Laplace equation. Our experimental tests using this method with model samples show promising results, which are well supported by those obtained using FESEM (fild emission scanning electron microscope), AFM (atomic force microscope), and conventional liquid⁻liquid displacement porometry. This novel method can provide useful information for not only surface coatings on porous substrates but also for modification of dense membrane defects; thus, broad utilizations of this technique can be expected in future study.

Ultrahigh vacuum dc magnetron sputter-deposition of epitaxial Pd(111)/Al2O3(0001) thin films

Pd(111) thin films, ∼245 nm thick, are deposited on Al₂O₃(0001) substrates at ≈0.5T_m, where T_m is the Pd melting point, by ultrahigh vacuum dc magnetron sputtering of Pd target in pure Ar discharges. Auger electron spectra and low-energy electron diffraction patterns acquired in situ from the as-deposited samples reveal that the surfaces are compositionally pure 111-oriented Pd. Double-axis x-ray diffraction (XRD) ω-2θ scans show only the set of Pd 111 peaks from the film. In triple-axis high-resolution XRD, the full width at half maximum intensity Γ_ω of the Pd 111 ω-rocking curve is 630 arc sec. XRD 111 pole figure obtained from the sample revealed six peaks 60°-apart at a tilt angles corresponding to Pd 111 reflections. XRD ϕ scans show six 60°-rotated 111 peaks of Pd at the same ϕ angles for 11[Formula: see text]3 of Al₂O₃ based on which the epitaxial crystallographic relationships between the film and the substrate are determined as [Formula: see text]ǁ[Formula: see text] with two in-plane orientations of [Formula: see text]ǁ[Formula: see text] and [Formula: see text]ǁ[Formula: see text]. Using triple axis symmetric and asymmetric reciprocal space maps, interplanar spacings of out-of-plane (111) and in-plane (11[Formula: see text]) are found to be 0.2242 ± 0.0003 and 0.1591 ± 0.0003 nm, respectively. These values are 0.18% lower than 0.2246 nm for (111) and the same, within the measurement uncertainties, as 0.1588 nm for (11[Formula: see text]) calculated from the bulk Pd lattice parameter, suggesting a small out-of-plane compressive strain and an in-plane tensile strain related to the thermal strain upon cooling the sample from the deposition temperature to room temperature. High-resolution cross-sectional transmission electron microscopy coupled with energy dispersive x-ray spectra obtained from the Pd(111)/Al₂O₃(0001) samples indicate that the Pd-Al₂O₃ interfaces are essentially atomically abrupt and dislocation-free. These results demonstrate the growth of epitaxial Pd thin films with (111) out-of-plane orientation with low mosaicity on Al₂O₃(0001).

Review of Supported Pd-Based Membranes Preparation by Electroless Plating for Ultra-Pure Hydrogen Production

In the last years, hydrogen has been considered as a promising energy vector for the oncoming modification of the current energy sector, mainly based on fossil fuels. Hydrogen can be produced from water with no significant pollutant emissions but in the nearest future its production from different hydrocarbon raw materials by thermochemical processes seems to be more feasible. In any case, a mixture of gaseous compounds containing hydrogen is produced, so a further purification step is needed to purify the hydrogen up to required levels accordingly to the final application, i.e., PEM fuel cells. In this mean, membrane technology is one of the available separation options, providing an efficient solution at reasonable cost. Particularly, dense palladium-based membranes have been proposed as an ideal chance in hydrogen purification due to the nearly complete hydrogen selectivity (ideally 100%), high thermal stability and mechanical resistance. Moreover, these membranes can be used in a membrane reactor, offering the possibility to combine both the chemical reaction for hydrogen production and the purification step in a unique device. There are many papers in the literature regarding the preparation of Pd-based membranes, trying to improve the properties of these materials in terms of permeability, thermal and mechanical resistance, poisoning and cost-efficiency. In this review, the most relevant advances in the preparation of supported Pd-based membranes for hydrogen production in recent years are presented. The work is mainly focused in the incorporation of the hydrogen selective layer (palladium or palladium-based alloy) by the electroless plating, since it is one of the most promising alternatives for a real industrial application of these membranes. The information is organized in different sections including: (i) a general introduction; (ii) raw commercial and modified membrane supports; (iii) metal deposition insights by electroless-plating; (iv) trends in preparation of Pd-based alloys, and, finally; (v) some essential concluding remarks in addition to futures perspectives.