Hydrogen
has a potential to be a clean energy carrier that emits
only water after combustion and can be produced from diverse feedstocks.
Hydrogen has much better combustion characteristics in conventional
combustion systems and higher energy efficiency when used with fuel
cells. More than 75 million tons of hydrogen are currently produced
primarily using fossil fuels as feedstock via steam methane reforming
processes. Steam methane reforming is the mature technology for producing
hydrogen and when coupled with CO2 capture can help address
climate challenges. Inorganic palladium (Pd) membranes have demonstrated
great potential to separate hydrogen due to their stability and high
selectivity for hydrogen. In this review, several methods of fabricating
Pd-alloy membranes are discussed and compared in terms of membrane
stability and selectivity of hydrogen. Such methods include electroless
plating (ELP), chemical vapor deposition (CVD), physical vapor deposition
(PVD), and electroplating deposition (EPD). The permeability of hydrogen
in different Pd-based alloy membranes are presented and compared.
Focus has been made, in this review, on Pd–Ag, Pd–Cu,
Pd–Au, and Pd–Ru alloys. The effects of impurities (H2S, CO, O2, and CO2) on performance of
different Pd-based alloy membranes are also investigated. Moreover,
the subject of using Pd-membrane reactors for fuel reforming and H2 production is investigated in detail based on numerous experimental
and numerical studies in the literature, considering different membrane
reactor designs: axial-flow tubular, radial-flow tubular, axial-flow
spherical, packed-bed, fluidized bed, and slurry bubble column. The
performance of Pd-membranes in such reactors for hydrogen production
is compared, and the effects of temperature, pressure, H2O/CH4 ratio, and residence time on reformer performance
are also investigated. Finally, the use of computational methods,
particularly, density functional theory (DFT), to complement well-established
experimental methods for studying the diffusion of H and its isotopes
in different metals is reviewed. The review concludes with some insights
into future work to bring Pd-membrane reactors to the level required
for hydrogen production at the commercial level.