Hydrothermally stable silica–alumina composite membranes for hydrogen separation

A thin layer (30–40 nm) of a dual-element silica–alumina composition was deposited on a porous alumina support by chemical vapor deposition (CVD) in an inert atmosphere at high temperature. Prior to CVD, an intermediate layer of γ-alumina was coated on the macroporous alumina support. The intermediate layer was prepared by the dip-coating and calcination of boehmite sols of different sizes to give a graded structure that was substantially free of defects. The resulting supported composite membrane had high permeance for hydrogen in the order of 2–3 × 10−7 mol m−2 s−1 Pa−1 at 873 K with selectivities of H2 over CH4, CO and CO2 of 940, 700 and 590, respectively. The membrane operated by a hopping mechanism involving jumps of permeating molecules between solubility sites. The presence of aluminum improved the hydrothermal stability of the membranes for periods in excess of 500 h at 873 K in 16% steam, allowing the permeance to remain above 10−7 mol m−2 s−1 Pa−1, although with decreased selectivities.