MIT filter resists 1,000 Kelvin heat to cut hydrogen production cost

MIT engineers have developed a novel palladium-based membrane filter that can withstand temperatures up to 1,000 kelvins, significantly surpassing the 800-kelvin limit of conventional palladium membranes used in hydrogen production. Palladium is prized for its ability to selectively allow hydrogen molecules to pass while blocking other gases, a critical function in hydrogen fuel generation. The breakthrough comes from redesigning the membrane’s structure: instead of a continuous palladium film that degrades at high heat, the new membrane features palladium deposited as “plugs” within the pores of a silica support. This plug design prevents the metal from shrinking or clumping under extreme temperatures, maintaining stability and hydrogen separation efficiency even after 100 hours of testing at 1,000 kelvins. This enhanced thermal resilience—an improvement of about 200 kelvins—makes the membrane particularly suitable for high-temperature hydrogen-generating processes like steam methane reforming and ammonia cracking, which are essential for producing zero-carbon fuel and electricity