Presented by: Jim Acquaviva Pall Corporation April 1, 2008 Performance Claims Define the Product Commercialization of a Pd Alloy Membrane for H2 Production NHA Hydrogen Conference 2008 Presented by: Jim Acquaviva Pall Corporation April 1, 2008 Photo courtesy of Pall Corporation This presentation does not contain any proprietary or confidential information

Contributors Acknowledgments Pall Corporation Jim Acquaviva Scott Hopkins Rick Kleiner Rajinder P. Singh Colorado School of Mines Mathew K. Keeling Paul M. Thoen J. Douglas Way DOE (EERE) Arlene Anderson Carolyn Elam Jill Gruber

Application Triangle MEMBRANE PROCESS FLUID OPERATING CONDITIONS Significant differences between applications All three can have variability Highly inter-dependent as all three need to be in balance for optimized process efficiency

Why Membrane ? Capital and operating cost for a hydrogen production system can potentially be reduced through process intensification Simple, compact separation systems can be designed using membranes Membranes that can be operated at high temperatures allow for integration with high temperature processes reducing energy consumed for cooling or compression

Why Palladium Membrane ? Established Feasibility Lee, D., Zhang, L., Oyama, S. T., Niu, S., and R. F Saraf, J. Membr. Sci., 231, 117(2004). Kajiwara, M., Uemiya, S., Kojima, T., and E. Kikuchi, Catal. Today, 56, 65(2000). DeVos, R. M. and H. Verweij, Science, 279, 1710(1998). Hassan, M. H., J. D. Way, P. M. Thoen, and A. C. Dillon, J. Membr. Sci. , 104, 27(1995). Polymer line from : Robeson, L. M., J. Membr. Sci., 62, 165(1991).

Research  Development  Manufacturing Discovery and feasibility Development Viability and practicality Manufacturing Material cost, labor content, utilization, overheads & yield Commercialization Gap Commercial viability = Profitable $ales Profit = Sales price – Cost Sales price = value add Cost = Variables (Mfg.) + Non-variables (cost of sales)

Steps Towards Commercialization Development Photo courtesy of Pall Corporation Research Scale up Commercialization Photo courtesy of Pall Corporation Transition to Manufacturing Photo courtesy of Pall Corporation Photo courtesy of Pall Corporation

Claims Define the Product R&D Drivers What are the customer needs and/or technology gaps? How can needs be met/gaps filled in a novel and useful way? What is IT ? It is a product It does something It must meet customer expectations It must meet corporate expectations Claims define what IT is ! Manufacturing Drivers How can yield be maximized ? How can costs be minimized ?

Basis for Product Claims Physical characteristics Defines key attributes Size and shape Materials of construction Operating limits (pressure/temperature) Functionality Specific to stated conditions Flux Separation factor Durability Sets customer expectations Establishes criteria for manufacturing

R&D Aims at Targets 2010 DOE / EERE Targets for Dense Metallic Membrane* Flux: 250scfh/ft2 @ 20 psi & 400oC Module Cost: $1,000/ft2 Durability: 3 years Operating pressure: 400 PSI H2 Recovery: > 80% H2 quality: 99.99 % Targets are not claims ! * As per the Multi-Year RD&D Plan Updated 11/14/06 http://www1.eere.energy.gov/hydrogenandfuelcells/mypp/pdfs/production.pdf

Feasibility Established Based on Targets

Development Identifies Variability Variability can come from different sources Materials Environment Processing methods and conditions Variability can come in at any stage for a composite membrane Substrate Diffusion barrier layer Functional layer (Pd alloy) Development phase identifies “cause & effect” to anticipate and control variation Controlling factors Metrics Functional ranges

Components of a Composite Membrane 3) Pd alloy membrane Functional layer provides for gas separation Critical features: thickness, alloy composition, durability and number of defects 2) Diffusion barrier Enables formation of functional layer Critical features: surface properties, material, gas permeability, number of defects 3 2 1 1) Porous Stainless Steel Provides mechanical support that can withstand the operating conditions of the process Critical features: permeability,weld configuration,mechanical, thermal and chemical compatibility

Claims Account For Cumulative Variability Manufacturing Focus Manufacturing Specifications Covers full range of cumulative variability Control Validation of Functionality Product Claim (always to be exceeded) - + Range of Variability Development Focus Performance Target Research Focus

Application Triangle MEMBRANE PROCESS FLUID OPERATING CONDITIONS Significant differences between applications All three can have variability Highly inter-dependent as all three need to be in balance for optimized efficiency

Conclusions Need to understand the interdependency between the membrane, process fluid and operating conditions for any given application Application specific targets can be used during the research phase to establish feasibility Identification of the sources of variability and methods of control during the development phase can expedite commercialization Commercialization/manufacturing phase requires controlled and profitable membrane production Manufacturing process is controlled and stable Product claims account for all variability Functionality of the product validated

Questions ? Thank You !