Diffusion barrier coating using a newly developed blowing coating method for a thermally stable Pd membrane deposited on porous stainless-steel support

Abstract

In this study, we present an intermetallic diffusion barrier coating using a newly developed blowing coating method for a thermally stable Pd-based composite membrane on porous stainless steel (PSS). A tubular PSS sample with 1/2 inch (12.7 mm) in diameter and 450 mm in length was used for the support. The support was welded with a stainless-steel cap and a 450-mm-long stainless-steel tube for each end. Before the diffusion barrier coating, the large-sized entrance pores were gradually blocked with sub-micron (similar to 500 nm) and nano (50 80 nm) yttria stabilized zirconia (YSZ). 8YSZ, i.e., 8wt.% YSZ, was used for the interdiffusion barrier material and dispersed on the surface of the pre-treated PSS using the blowing coating method. The blowing coating method has 4 steps: (i) spraying the 17 wt. % 8YSZ paste on the surface of the PSS tube,(ii) blowing the paste using compressed air,(iii) drying at room temperature, and (iv) heat treatment at 923 K for 2 h in air. Steps (i) and (ii) were repeated 3 times to have a similar to 240 nm thick 8YSZ layer. A thin palladium layer (similar to 3 mu m) was deposited on the pre-treated PSS using electroless plating, and the membrane stability was tested at 673-773 K for similar to 200 h. A hydrogen permeation flux of 9.86 x 10(-2) mol m(-2) s(-1) and an H-2/N-2 selectivity of 595 were obtained at 773 K and a transmembrane pressure difference of 20 kPa. The surface and cross-sectional SEM/EDX analysis confirmed that the 8YSZ layer sufficiently prevented the interdiffusion between Pd and PSS elements, such as Fe, Cr and Ni.