Abstract: A method for fabricating a composite gas separation module includes depositing a preactivated powder over a porous substrate; depositing a binder metal onto the preactivated powder; and depositing a dense gas-selective membrane to overlie the preactivated powder and binder metal, thereby forming the composite gas separation module. The preactivated powder can be, for example, selected from the group consisting of preactivated metal powders, preactivated metal oxide powders, preactivated ceramic powders, preactivated zeolite powders, and combinations thereof. The preactivated powder can be deposited, for example, from a slurry such as a water-based slurry. In some embodiments, the dense gas-selective membrane is a dense hydrogen-selective membrane.

Abstract: A composite gas separation module includes a porous substrate; an intermediate layer at the porous substrate that includes particles and a binder metal, wherein the binder metal is uniformly distributed throughout the intermediate layer; and a dense gas-selective membrane, wherein the dense gas-selective membrane overlies the intermediate layer. In one embodiment, the intermediate layer includes a gradient of particle size from a surface of the intermediate layer proximate to the porous substrate to a surface of the intermediate layer distal to the porous substrate. The particles of the intermediate layer can include particles selected from the group consisting of metal particles, metal oxide particles, ceramic particles, zeolite particles, and combinations thereof.