Tech
Palladium filters could enable cheaper, more efficient generation of hydrogen fuel
Palladium is one of the keys to jump-starting a hydrogen-based energy economy. The silvery metal is a natural gatekeeper against every gas except hydrogen, which it readily lets through. For its exceptional selectivity, palladium is considered one of the most effective materials at filtering gas mixtures to produce pure hydrogen.
Today, palladium-based membranes are used at commercial scale to provide pure hydrogen for semiconductor manufacturing, food processing, and fertilizer production, among other applications in which the membranes operate at modest temperatures. If palladium membranes get much hotter than around 800 Kelvin, they can break down.
Now, MIT engineers have developed a new palladium membrane that remains resilient at much higher temperatures. Rather than being made as a continuous film, as most membranes are, the new design is made from palladium that is deposited as “plugs” into the pores of an underlying supporting material. At high temperatures, the snug-fitting plugs remain stable and continue separating out hydrogen, rather than degrading as a surface film would.
The thermally stable design opens opportunities for membranes to be used in hydrogen-fuel-generating technologies such as compact steam methane reforming and ammonia cracking—technologies that are designed to operate at much higher temperatures to produce hydrogen for zero-carbon-emitting fuel and electricity.
“With further work on scaling and validating performance under realistic industrial feeds, the design could represent a promising route toward practical membranes for high-temperature hydrogen production,” says Lohyun Kim Ph.D. ’24, a former graduate student in MIT’s Department of Mechanical Engineering.
Kim and his colleagues report details of the new membrane in a study appearing today in the journal Advanced Functional Materials. The study’s co-authors are Randall Field, director of research at the MIT Energy Initiative (MITEI); former MIT chemical engineering graduate student Chun Man Chow Ph.D. ’23; Rohit Karnik, the Jameel Professor in the Department of Mechanical Engineering at MIT and the director of the Abdul Latif Jameel Water and Food Systems Lab (J-WAFS); and Aaron Persad, a former MIT research scientist in mechanical engineering who is now an assistant professor at the University of Maryland Eastern Shore.
Compact future
The team’s new design came out of a MITEI project related to fusion energy. Future fusion power plants, such as the one MIT spinout Commonwealth Fusion Systems is designing, will involve circulating hydrogen isotopes of deuterium and tritium at extremely high temperatures to produce energy from the isotopes’ fusing. The reactions inevitably produce other gases that will have to be separated, and the hydrogen isotopes will be recirculated into the main reactor for further fusion.
Similar issues arise in a number of other processes for producing hydrogen, where gases must be separated and recirculated back into a reactor. Concepts for such recirculating systems would require first cooling down the gas before it can pass through hydrogen-separating membranes—an expensive and energy-intensive step that would involve additional machinery and hardware.
“One of the questions we were thinking about is: Can we develop membranes which could be as close to the reactor as possible, and operate at higher temperatures, so we don’t have to pull out the gas and cool it down first?” Karnik says. “It would enable more energy-efficient, and therefore cheaper and compact, fusion systems.”
The researchers looked for ways to improve the temperature resistance of palladium membranes. Palladium is the most effective metal used today to separate hydrogen from a variety of gas mixtures. It naturally attracts hydrogen molecules (H2) to its surface, where the metal’s electrons interact with and weaken the molecule’s bonds, causing H2 to temporarily break apart into its respective atoms. The individual atoms then diffuse through the metal and join back up on the other side as pure hydrogen.
Palladium is highly effective at permeating hydrogen, and only hydrogen, from streams of various gases. But conventional membranes typically can operate at temperatures of up to 800 Kelvin before the film starts to form holes or clumps up into droplets, allowing other gases to flow through.
Plugging in
Karnik, Kim and their colleagues took a different design approach. They observed that at high temperatures, palladium will start to shrink up. In engineering terms, the material is acting to reduce surface energy. To do this, palladium, and most other materials and even water, will pull apart and form droplets with the smallest surface energy. The lower the surface energy, the more stable the material can be against further heating.
This gave the team an idea: If a supporting material’s pores could be “plugged” with deposits of palladium—essentially already forming a droplet with the lowest surface energy—the tight quarters might substantially increase palladium’s heat tolerance while preserving the membrane’s selectivity for hydrogen.
To test this idea, they fabricated small chip-sized samples of membrane using a porous silica supporting layer (each pore measuring about half a micron wide), onto which they deposited a very thin layer of palladium. They applied techniques to essentially grow the palladium into the pores, and polished down the surface to remove the palladium layer and leave palladium only inside the pores.
They then placed samples in a custom-built apparatus in which they flowed hydrogen-containing gas of various mixtures and temperatures to test its separation performance. The membranes remained stable and continued to separate hydrogen from other gases even after experiencing temperatures of up to 1,000 Kelvin for over 100 hours—a significant improvement over conventional film-based membranes.
“The use of palladium film membranes are generally limited to below around 800 Kelvin, at which point they degrade,” Kim says. “Our plug design therefore extends palladium’s effective heat resilience by roughly at least 200 Kelvin and maintains integrity far longer under extreme conditions.”
These conditions are within the range of hydrogen-generating technologies such as steam methane reforming and ammonia cracking.
Steam methane reforming is an established process that has required complex, energy-intensive systems to preprocess methane to a form where pure hydrogen can be extracted. Such preprocessing steps could be replaced with a compact “membrane reactor,” through which a methane gas would directly flow, and the membrane inside would filter out pure hydrogen.
Such reactors would significantly cut down the size, complexity, and cost of producing hydrogen from steam methane reforming, and Kim estimates a membrane would have to work reliably in temperatures of up to nearly 1,000 Kelvin. The team’s new membrane could work well within such conditions.
Ammonia cracking is another way to produce hydrogen, by “cracking” or breaking apart ammonia. As ammonia is very stable in liquid form, scientists envision that it could be used as a carrier for hydrogen and be safely transported to a hydrogen fuel station, where ammonia could be fed into a membrane reactor that again pulls out hydrogen and pumps it directly into a fuel cell vehicle.
Ammonia cracking is still largely in pilot and demonstration stages, and Kim says any membrane in an ammonia cracking reactor would likely operate at temperatures of around 800 Kelvin—within the range of the group’s new plug-based design.
Karnik emphasizes that their results are just a start. Adopting the membrane into working reactors will require further development and testing to ensure it remains reliable over much longer periods of time.
“We showed that instead of making a film, if you make discretized nanostructures you can get much more thermally stable membranes,” Karnik says. “It provides a pathway for designing membranes for extreme temperatures, with the added possibility of using smaller amounts of expensive palladium, toward making hydrogen production more efficient and affordable. There is potential there.”
More information:
Nanostructured Hydrogen-Selective Palladium “Plug” Membranes Capable of Withstanding High Temperatures, Advanced Functional Materials (2025). advanced.onlinelibrary.wiley.c … .1002/adfm.202516184
This story is republished courtesy of MIT News (web.mit.edu/newsoffice/), a popular site that covers news about MIT research, innovation and teaching.
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Tech
A Single Strike Won’t Shut Off the Gulf’s Desalination System
Across the region, facilities tied to water and power—including desalination plants—have been damaged or exposed to risk as Iranian strikes extend beyond traditional targets.
A single strike, however, is unlikely to shut off the gulf’s water supply. The system is designed to absorb isolated disruption, but sustained or multisite attacks would begin to strain supply far more quickly.
“In the Gulf, desalination is built with enough breathing room that losing one plant doesn’t immediately show up at the tap,” says Rabee Rustum, professor of water and environmental engineering at Heriot-Watt University Dubai.
In Kuwait, Iranian drone attacks have damaged two power and desalination facilities and ignited fires at two oil sites. Other sites, including Fujairah in the UAE, have been identified as potentially exposed.
“Striking desalination plants would be a strategic move, but it would also come very close to, and in some cases cross, a red line,” says Andreas Krieg, senior lecturer at the School of Security Studies at King’s College London.
Water infrastructure, Krieg explains, occupies a distinct category. “Water infrastructure is not just another utility. In places that depend on desalination, it underpins civilian survival, public health, hospital function, sanitation, and basic state legitimacy.”
Krieg notes that international humanitarian law gives special protection to civilian objects and to objects indispensable to the survival of the civilian population. “Which is precisely why attacks on water systems carry such grave legal and moral weight,” Krieg adds.
The incidents highlight a structural reality: Desalination is central to water supply in the gulf, and disruption carries immediate implications for daily life.
How the System Absorbs Disruption
At first glance, desalination appears vulnerable. Shut down a plant, and supply is reduced. In practice, the system is designed with layers of redundancy.
Plants operate across multiple locations, allowing output to be redistributed if one facility slows down. Water is also stored at different points across the network, including central reservoirs and building-level tanks, creating a buffer that delays disruption.
According to a statement to WIRED Middle East by Veolia, an environmental services provider whose technologies account for nearly 19 percent of desalination capacity in the region, “the region’s water supply is diversified thanks to a network of numerous facilities distributed along the coastline.”
The company adds that distribution systems are interconnected, allowing plants to “support and substitute for one another when necessary,” helping maintain continuity of service.
In the UAE, storage capacity typically covers around one week, while in other parts of the region it may be limited to two to three days, Veolia says.
In practice, this means the system can absorb disruption for a limited period. Once reserves are depleted, water supply depends on whether plants can continue producing enough water to meet demand.
The System That Produces Water
Unlike most regions, the Gulf does not rely on rivers or rainfall. It depends on a network of desalination plants along its coastline that convert seawater into potable water on a continuous basis.
Seawater is drawn into treatment facilities, filtered and processed either through reverse osmosis—forcing it through membranes to remove salt and impurities—or through thermal methods that evaporate and condense water. The resulting supply is distributed through pipelines, stored in reservoirs, and delivered to homes, hospitals, and industry.
This is not a flexible system. It is designed to operate continuously, producing water at a scale that sustains cities, industrial activity, and essential services. Gulf states produce roughly 40 percent of the world’s desalinated water, operating more than 400 plants across the region.
Dependence varies by country but is high everywhere. In the UAE, desalination accounts for 41 to 42 percent of total water supply, while in Kuwait, it provides around 90 percent of drinking water, and in Saudi Arabia, approximately 70 percent.
When Disruption Becomes Visible
For residents, disruption would not be felt immediately—water would continue to flow.
Rustum explains that buildings are supported by internal storage and pumping systems, meaning early changes in supply may not be apparent. In many cases, water pressure remains stable, even as the wider system adjusts.
Tech
Border Patrol Agents Sold Challenge Coins With ‘Charlotte’s Web’ Characters in Riot Gear
US Border Patrol agents are raising money by selling coins that commemorate last year’s wave of immigration enforcement “operations” across the country, along with other merchandise. The funds are for nonprofit organizations that list Border Patrol buildings as their address in IRS paperwork. At least two of the organizations have dedicated US Customs and Border Protection email addresses.
The front side of one coin for sale reads, “NORTH AMERICAN TOUR 2025,” along with the acronyms for US Border Patrol and the acronym for “fuck around and find out”—a phrase that was initially popularized by the far-right group the Proud Boys and has been used by various Trump officials. In the center, the coin depicts a gas mask, a riot control smoke grenade, and a pepper ball launcher. On the other side, the coin appears to have a portrait of Border Patrol’s now retired commander-at-large, Gregory Bovino, with his arm raised in a salute, along with the text “COMING TO A CITY NEAR YOU!” It lists seven cities, many of which actually saw federal enforcement surges in 2025: Chicago, Los Angeles, Memphis, Phoenix, Portland, Charlotte, and Atlanta.
The coin is for sale by Willcox Morale Welfare and Recreation, a nonprofit that the IRS most recently declared tax-exempt during the Biden administration and whose address on IRS paperwork matches that of the Willcox Border Patrol Station in Arizona. A request for comment sent to Willcox MWR’s dedicated CBP email address went unanswered.
Employees of the Department of Homeland Security, the parent agency for Border Patrol, are allowed to start private, not-for-profit employee associations within DHS, so long as they get formally recognized by the agency and follow certain rules. According to DHS policies, officially recognized groups can fundraise using government property and create merchandise with the agency’s name and logos–but they have to receive advance approval from the agency.
Willcox MWR is just one of several groups across the country that cater to Border Patrol agents and refer to themselves as MWRs, a reference to the US military’s “morale, welfare and recreation” programs. The groups tend to throw holiday events and retirement parties, and sometimes raise money for the families of agents going through hard times, including those not getting paid during the current shutdown.
Many MWRs also sell customized medallions known as “challenge coins” that commemorate specific teams or events. While anyone, including CBP alumni, can design and sell coins, current DHS employees are not supposed to use government resources to sell ones that use the agency’s seals or logos without permission, or ones that the agency considers inappropriate or unprofessional.
CBP did not provide comment about its relationship to Willcox MWR or any other nonprofit mentioned in this story, nor whether the agency had green-lit the “North American Tour” coin design, ahead of publication.
Under Willcox MWR’s Facebook post about the “North American Tour” coin, someone named Juan Diego commented, “Sign up SDC BK5 MWR for 10.”
“Shoot us an email,” someone managing the Willcox MWR account replied, giving out what appeared to be a dedicated cbp.dhs.gov email address for the group.
SDC BK5 MWR, also a registered nonprofit, lists an address on its website that matches that of a government facility in Chula Vista, California. It says on its site that it was started by San Diego Sector Border Patrol agents and sells custom merchandise “designed to raise funds for morale and relief efforts.”
Diego did not respond to a request for comment.
The SDC BK5 MWR website has listings for over 200 different products in addition to the North American Tour coin. One of those listings was a “Chicago Midway Blitz” challenge coin in the shape of a gas mask that doubles as a bottle opener. Embossed around the edges of the coin are the names of several municipalities and neighborhoods caught up in DHS’s immigration enforcement surge of the same name last fall. Like the North American Tour coin, it features the US Border Patrol logo and the acronym for “fuck around and find out.” Opponents of the Trump administration’s immigration enforcement activity in Illinois are unamused.
Tech
One of Our Favorite 360 Cams Is 35 Percent Off
Tired of taking your action camera on an adventure, only to get home and find out you missed the action with a bad angle? One option is to switch to a 360-degree action cam, so you can capture all of the action and then edit down to just the good stuff later. One of our favorite options, the DJI Osmo 360, is currently available for just $390 on Amazon, a $209 discount from its usual price, and it comes with a selfie stick and an extra battery.
The DJI Osmo 360 achieves its impressive all-around video quality by leveraging a pair of 1/1.1-inch sensors, larger than some other offerings, and by supporting 10-bit color. You can really see that in the camera’s output, with colors that are vivid and bold, to the point that you may need to dial them back a bit in post if you want something more natural. With support for up to 50 frames per second at 8K when recording in 360 degrees, or 120 fps at 4K when shooting with only one sensor, you’ll have plenty of material to work with. In our testing, it ran for just shy of two hours at 30 fps, which is also around the time the internal storage had filled up anyway.
If you plan on catching any serious discussions with your Osmo 360, you’ll be pleased to know it connects directly to DJI’s line of wireless lavalier microphones, including the excellent and frequently discounted DJI Mic 2 and Mic Mini. If you want to mount it to something other than the included 1.2-meter selfie stick, it has both DJI’s magnetic attachment system and a more traditional ¼”-20 tripod mount. The DJI Mimo app lets you control the camera and adjust any settings, and there’s even a simple editor for on-the-fly production. For desktop users, DJI Studio has even more in-depth settings and editing options, in case you don’t want to pay for Premiere.
The DJI Osmo 360 is one of our favorite action cameras, and is particularly appealing at the discounted price point, but make sure to check out our full review for more info, or head over to our full roundup to see what else is available.
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