1. 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

2. 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

3. 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

4. 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

5. 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).

6. 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)

7. 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

8. 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 ?

9. 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

10. R&D Aims at Targets
2010 DOE / EERE Targets for Dense Metallic Membrane*
Flux: 20 psi & 400oC
Module Cost: $1,000/ft2
Durability: 3 years
Operating pressure: 400 PSI
H2 Recovery: > 80%
H2 quality: %
Targets are
not claims !
* As per the Multi-Year RD&D Plan Updated 11/14/06

11. Feasibility Established Based on Targets

12. 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

13. 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

14. 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

15. 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

16. 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

17. Questions ?
Thank You !