Palladium and palladium/alloy membranes
have shown to be an effective
technology option for the production of pure hydrogen. In particular,
Pd/Au membranes have displayed superior chemical stability and separation
performance. However, the lack of industrial operating experience
gives rise to technological uncertainties such as the lifetime of
the membranes which could potentially prevent the deployment of this
new technology option. In light of the above recognition, the primary
aim of the present research work is to combine long-term H2 membrane permeance and He leak characterization tests (cumulative
testing over 2.2 years) conducted to estimate the lifetime of composite
asymmetric Pd/Au membranes at different thicknesses with a comprehensive
economic performance assessment framework in the presence of inherent
trade-offs between permeance, thickness, and membrane lifetime. The
experimental results are depicted in terms of the produced H2 purity and flux at different testing times and various membrane
thickness values. Using these experimental results, the lifetime of
the membranes is estimated and integrated into the proposed economic
assessment framework. The economic evaluation framework for H2 separation units is structured in a way that explicitly recognizes
various uncertainty sources via Monte Carlo simulation techniques
and assesses economic performance based on metrics such as fixed capital
investment (FCI), total capital investment (TCI), total product cost
(TPC), and the levelized H2 cost (LC). It is shown that
the expected values of the derived FCI/TCI and LC profiles increase
as the Pd layer thickness increases while the TPC profile decreases
with higher Pd layer thicknesses. Finally, tornado diagrams for the
LC are generated to characterize comparatively the importance of H2 permeance and membrane lifetime on the membrane system’s
economic performance profile.