A polymeric gas separation membrane utilizing polybenzimidazole (PBI) based on 4,4'-(hexafluoroisopropylidene)bis(benzoic acid) (HFA) with an effective permeating area of 8.3 cm2 and a thickness of 30(± 2) mm was prepared and its gas permeation properties were investigated using H2, CO2, CO, and N2 at various temperatures ranging from 24 to 200 oC. The PBI-HFA membrane not only exhibited excellent H2 permeability, but it also displayed superior gas separation performance particularly for H2/N2 and H2/CO2. The permeation parameters for both permeability and selectivity ( PH2 and α(H2/N2); PH2 and α(H2/CO2)) obtained for the new material were found to surpass those reported by Robeson in 2008. The gas permeation properties of the prepared membrane were found to be dependent on trans-membrane pressure difference as well as temperature. A gas-tight palladium (Pd) membrane was fabricated on a PBI-HFA membrane by a vacuum electroless plating technique (VELP). The thickness and effective permeating area of the Pd/PBI-HFA membrane were estimated in the range of 228–261 nm, and 8.3 cm2, respectively. The Pd membrane prepared using the VELP technique had a more uniform microstructure than those manufactured by a conventional electroless plating method (CELP), with no delamination or agglomerated Pd particles observed. The gas permeation properties of the prepared Pd membranes were evaluated using H2, N2, CO2, and CO as functions of:35 to 200 °C temperature, 0.4 to 0.8 MPa pressure difference, and membrane preparation methods including CELP, VELP, and VELP following a H2O2 surface treatment (H-VELP). The Pd film fabricated by the H-VELP method showed superior performance, and proved to be impermeable to nitrogen as well as carbon monoxide. Additionally, the Pd membranes prepared by H-VELP with a 228 nm thickness also demonstrated an excellent gas tightness with an infinite H2/N2 permselectivity, and its separation performance was above the Robeson’s 2008 upper bound.
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