Patent Description:
Sealing of Pd-based (Palladium-based) membrane layers deposited on ceramic tubular supports represents a challenging task: preliminary tests showed gas leak problems after some thermal cycles, due to the detachment of the Pd membrane layer that is deposited on the glass used to connect the ceramic dense and porous parts. This leakage would decrease the separation efficiency of the membranes and thus the quality of the hydrogen produced. Solving this problem will make the membranes closer to industrial applications.

Chen et al. (<NPL>) described a method using graphite ferrules instead of using standard metal ferrules. The authors have shown that these graphite ferrules could successfully seal the membrane with Swagelok® connectors. Even at very high pressures up to <NUM> bar, the nitrogen leakage rate over the connectors was only about <NUM>/min. To seal the membranes with Swagelok® fittings of <NUM> mml. (code: SS-10M0-<NUM>), graphite ferrules of <NUM> I. (purchased from CHROMalytic TECH(nology) Pty Ltd) were used instead of the standard metal ones. Ferrules were opened from inside with a rotating cutter with sharp edges to in-crease the inner diameter of the ferrules in order to make them fit to the membranes (with an O. between <NUM> and10. Before sealing the membrane with the opened ferrules, the ferrules were first conditioned in the Swagelok® fitting with a dummy Stainless steel (<NUM>) rod to form the ferrules to the right shape. The diameter of the dummy is equal to the diameter of the membrane to be sealed. The connectors were tightened with about <NUM>-<NUM> (torque wrench) to form them with the right shape and to get a smooth inner surface. Reference is made in this regard to Fernandez et al. See <FIG>, in which <FIG> shows a <NUM> dummy rod with graphite ferrule and <FIG> shows a connector with pre-treated ferrule (shiny inner surface), also with reference to Fernandez et al.

<FIG> shows a Pd membrane (E80 e PdeAg membrane, thickness <NUM> micron) before connecting to the Swagelok® connectors, while <FIG> shows the same membrane after connecting to the Swagelok® connectors. Again reference is made to Fernandez et al.

Although the sealing is effective in making the membrane more gas tight compared to previous cases, it is still a point of attention as most of the leakages are still coming from that zone. An extensive study on the stability of the membrane and sealing has been carried out showing that the membrane with <NUM> sealings has double the leakages than the one with <NUM> sealing. And the membrane where the sealing can be applied with higher torque, has less leakages that the one where the torque applied is less (see <FIG>, showing relative nitrogen permeance of the membranes 1a to <NUM> in the long-term membrane test. Reference is made to De Nooijer et al.

<CIT> relates to a gas sealing composite of a hydrogen production apparatus, including a first pair of ring members, a second ring member interposed between the first members, wherein the first members are heat resistent gaskets made from expanded graphite. The first members are compressed by the pressing pressure of a pressing bracket in a space and retained as such, wherein the second member is a glass ring. Such glass ring softens at the operating temperature of the hydrogen production apparatus and provides a gas sealing between the outer surface of a hydrogen separation cylinder and the inner surface of a bracket with the first members.

<CIT> relates to a hydrogen diffusion apparatus having a tube of palladium or palladium alloy extending through a wall thereof, the tube being secured to the wall by means of a gas tight fitting comprising a body portion wherein the body portion is connected, at one end, to the wall, and having, at the other end, a frusto-conical inner surface.

<CIT> relates to a detachable sample chamber device for a hydrogen storage material PCT tester including a sample chamber and a quick connection device, wherein the sample chamber includes a reactor, a reaction tube, a first connecting tube and second connecting tube, wherein the quick-connect device includes a casing and a sealing ring installed in the casing. One end of the reactor is detachably connected to an end of the first connecting pipe through a first nut assembly and another end of the first connecting pipe is detachably connected through a second nut assembly.

It is an object to develop a sealing method that decreases the leakages and is more stable and possibly reusable. It is an object to provide an improved coupling device and an improved combination and assembly of such a coupling device and a tube having a Palladium-based membrane deposited thereon. It is an object to provide a coupling device, combination and assembly of such a coupling device and a tube having a Palladium-based membrane deposited thereon, having an improved sealing.

According to the present invention, a coupling device is provided as defined in claim <NUM>. Embodiments of the coupling device are defined in the dependent claims.

The invention also relates to a combination as defined in claim <NUM> and an assembly as defined in claim <NUM>. Embodiments of the coupling device as defined below are also applicable to the combination and the assembly.

As defined in claim <NUM>, the invention provides a coupling device for a tube having a Palladium-based membrane deposited thereon, the tube for use in separation and purification of hydrogen in a hydrogen separator or reactor. The coupling device has an inlet for a gas and configured to couple said tube to the inlet so that the gas can be supplied via the inlet into the tube.

The coupling device comprises a body part with a cylindrical opening for receiving the tube, the opening being arranged to receive gas flow to the inlet. The coupling device also comprises a nut, wherein the body part and the nut being configured such that the nut can be screwed onto the body part at the opening. The coupling device further has a stack of at least two sealing rings provided between an end portion of the body part surrounding the opening and an axial end portion of the nut. The nut preferably radially encloses the stack of sealing rings on an outer side, i.e. outer circumference, thereof.

The body part, the nut and the stack of sealing rings are configured such that the tube extends through the axial end portion of the nut, through the stack of sealing rings and into the opening such that, in use, the stack of sealing rings is compressed in an axial direction of the stack as a result of screwing the nut onto the body part so that the sealing rings sealingly engage a circumferential surface of the tube.

The invention provides a sealing, i.e. a coupling device, for membranes that allows more area of contact between membrane and the sealing rings, such as graphite gaskets, and can use standard graphite rings. It allows operation with lower possibility of leakages and can be reused.

The inventors have found out that graphite ferrules are not good enough for ultra high hydrogen purity. The reason is the relatively small contact area between the membrane and the ferrule, as well as the small thickness of the ferrule. A new sealing has been developed that instead of using graphite ferrules uses a stack of sealing rings, such as a number of graphite rings, such that the area of contact with the membrane is increased. Additionally the pressure on the membrane is generated via an axial compression of the sealing rings which leads to a radial inward expansion of the sealing rings, thereby sealingly engaging the tube. So a higher torque can be applied and a better sealing can be achieved.

Preferably, the stack of sealing rings is a stack of two to eight sealing rings, preferably three to five sealing rings, preferably four sealing rings. A total axial length of the stack of sealing rings is preferably in the range of <NUM> to <NUM> times the outer diameter of the tube.

The material of construction (body part and nut) may be stainless steel, which is effective in particular for temperatures below <NUM> degrees C. The material of the body part and nut may be a low carbon alloy, which is effective in particular for higher temperatures. In an embodiment, treads on the body part and on the nut) may be coated with silver or ceramic to be able to open easily and reuse the sealing. For temperatures above <NUM> degrees C the graphite rings may be replaced by mica rings with the same shapes. In another embodiment, the sealing rings are copper rings.

In an embodiment, sealing rings of the stack are square or rectangular shaped O-rings.

According to the invention, the last sealing ring, preferably a graphite ring, has a shape such that possible leaking is minimized, which is achieved wherein a sealing ring of the stack of sealing rings, which sealing ring in use contacts the end portion of the body part surrounding the opening, is a square or rectangular shaped O-ring having an axially protruding tapered ridge, preferably a circumferential ridge, facing the end portion of the body part, wherein the end portion of the body part has a correspondingly tapered or chamfered portion for receiving therein the ridge. In an embodiment, the ridge and the tapered portion are dimensioned such that the ridge exerts a force having a radial component on the tapered portion as a result of axial compression of the sealing ring.

A metal ring may be added at the bottom so that, optionally together with one or more, such as three, small holes in the sealing body, one can easily remove the sealing rings and re-use much easily the sealing. These effects may be achieved by an embodiment further comprising a metal ring on top of the stack of sealing rings, the ring being arranged between the axial end portion of the nut and the stack, so that a compressive force is exerted from the axial end portion of the nut to the stack of sealing rings via the metal ring.

In an embodiment, threads on the nut and/or on the body part have a coating made of silver or graphite, the threads arranged to screw the nut on the body part.

The invention also relates to a combination, as defined in claim <NUM>, of a coupling device according to the present invention, and a tube having a Palladium-based membrane deposited thereon, for use in separation and purification of hydrogen in a hydrogen separator or reactor. In an embodiment, the tube is porous, preferably made of a ceramic material.

The invention also relates to an assembly comprising a coupling device according to the present invention, and a tube having a Palladium-based membrane deposited thereon, for use in separation and purification of hydrogen in a hydrogen reactor,
wherein the tube extends through the axial end portion of the nut, through the stack of sealing rings and into the opening, wherein the stack of sealing rings is compressed in an axial direction of the stack as a result the nut being screwed onto the body part so that the sealing rings sealingly engage a circumferential surface of the tube.

In an embodiment of the assembly, the tube is porous, preferably made of a ceramic material.

Embodiments of the coupling device according to the invention are also applicable to the combination and to the assembly according to the invention. Effects of the coupling device and embodiments thereof are applicable to the combination and assembly in an analogous manner.

The present invention is described hereinafter with reference to the accompanying schematic drawings in which an embodiment of the present invention are shown and in which like reference numbers indicate the same or similar elements.

The dimensions of the sealing, that means of the coupling device, depend on the membrane, that means of the tube having the membrane deposited thereon. <FIG> show an example of a coupling device <NUM> according to the invention, for <NUM> membranes. The same shape can be used from membranes of different size starting from <NUM> diameter. In embodiments, the coupling device is for use with tubes having an outer diameter in the range of <NUM> to <NUM>.

<FIG> show a coupling device <NUM> for a tube <NUM> having a Palladium-based membrane deposited thereon. The tube <NUM> is for use in separation and purification of hydrogen in a hydrogen separator or reactor. The tube <NUM> is porous and preferably made of a ceramic material. The coupling device <NUM> has an inlet <NUM> for a gas and configured to couple said tube <NUM> to the inlet <NUM> so that the gas can be supplied via the inlet <NUM> into the tube <NUM>. The supply of gas towards the inlet <NUM> may take place via an external tube <NUM> which is connected to the inlet <NUM> of the coupling device <NUM>, as <FIG> shows.

The coupling device <NUM> comprises a body part <NUM> with a cylindrical opening <NUM> for receiving the tube <NUM>. The opening <NUM> is arranged to receive gas flow to the inlet <NUM>. The coupling device <NUM> also comprises a nut <NUM>, wherein the body part <NUM> and the nut <NUM> are configured such that the nut <NUM> can be screwed onto the body part <NUM> at the opening <NUM>. The body part <NUM> and the nut <NUM> are made of a stainless steel or a low carbon alloy. The material of the nut <NUM> and of the body part <NUM> may be Inconel <NUM>. Threads <NUM> on the nut <NUM> and on the body part <NUM> may have a coating made of silver or graphite, the threads <NUM> arranged to screw the nut on the body part.

The coupling device <NUM> further has a stack <NUM> of at least two sealing rings <NUM>, <NUM>, in the example shown in the figures a number of three sealing rings <NUM> and one sealing ring <NUM>, the stack <NUM> being provided between an end portion <NUM> of the body part <NUM> surrounding the opening <NUM> and an axial end portion <NUM> of the nut <NUM>. The stack may have two to eight sealing rings, preferably three to five sealing rings, preferably four sealing rings as is the case in the example shown in the figures. The sealing rings <NUM>, <NUM> are made of graphite but may also be made of mica or copper. The sealing rings <NUM>, <NUM> of the stack <NUM> are rectangular, about square shaped, O-rings.

The body part <NUM>, the nut <NUM> and the stack <NUM> of sealing rings <NUM>, <NUM> are configured such that the tube extends through the axial end portion <NUM> of the nut, through the stack <NUM> of sealing rings and into the opening <NUM> such that, in use, the stack <NUM> of sealing rings <NUM>, <NUM> is compressed in an axial direction <NUM> of the stack <NUM> as a result of screwing the nut <NUM> onto the body part <NUM> so that the sealing rings <NUM>, <NUM> sealingly engage a circumferential surface <NUM> of the tube <NUM>.

At least in the example shown, the coupling device <NUM> further comprises an optional metal ring <NUM> on top of the stack <NUM> of sealing rings <NUM>, <NUM>. The material of the ring <NUM> may be stainless steel. The ring <NUM> is arranged between the axial end portion <NUM> of the nut <NUM> and the stack <NUM>, so that a compressive force is exerted from the axial end portion <NUM> of the nut <NUM> to the stack <NUM> of sealing rings <NUM>, <NUM> via the metal ring <NUM>. Also, the sealing ring <NUM> of the stack <NUM> of sealing rings <NUM>, <NUM>, which sealing ring <NUM> in use contacts the end portion <NUM> of the body part <NUM> surrounding the opening <NUM>, is a rectangular shaped O-ring having an axially protruding tapered ridge <NUM>, which is a circumferential ridge as in particular <FIG> shows, facing the end portion <NUM> of the body part <NUM>. The end portion <NUM> of the body part <NUM> has a correspondingly tapered or chamfered portion <NUM> for receiving therein the ridge <NUM>. The ridge <NUM> and the tapered portion <NUM> are dimensioned such that the ridge exerts a force having a radial component on the tapered portion as a result of axial compression of the sealing ring <NUM>.

In the example shown in the figures, the following dimensions may be chosen for use of the coupling device with a tube having an outer diameter of <NUM>, that means with a membrane of <NUM>. The specific dimensions are merely provided as an example. Other dimensions may be suitably chosen dependent on the size of the membrane and/or intended application. L1 may be a size <NUM> hex nut (L2 may in that case be <NUM>); L3 may be <NUM>; L4 may be <NUM>; L5 may be <NUM>; L6 may be <NUM>; L7 may be <NUM>; L8 may be <NUM> (or between <NUM> and <NUM>). ; L9 may be <NUM> (or between <NUM> and <NUM>); T1 may be a <NUM> x <NUM> thread (outer thread on the body part and corresponding inner thread on the nut); D1 may be <NUM>; D2, being the inner diameter of ring <NUM>, may be <NUM> (or between <NUM> and <NUM>); D3, being the outer diameter of ring <NUM>, may be <NUM> (or between <NUM> and <NUM>); diameter D4 may be <NUM> (or between <NUM> and <NUM>); angle a1 may be <NUM> degrees; angle a2 may be <NUM> degrees (or between <NUM> and <NUM> degrees). Each of the rings <NUM> may have an inner diameter of <NUM> (or between <NUM> and <NUM>), an outer diameter of <NUM> (or between <NUM> and <NUM>) and a thickness of <NUM> (or between <NUM> and <NUM>).

<FIG> shows an assembly <NUM> comprising the coupling device <NUM> and the tube <NUM> having a Palladium-based membrane deposited thereon, for use in separation and purification of hydrogen in a hydrogen reactor. The tube extends through the axial end portion of the nut, through the stack of sealing rings and into the opening, wherein the stack of sealing rings is compressed in an axial direction of the stack as a result the nut being screwed onto the body part so that the sealing rings sealingly engage a circumferential surface of the tube. The top part of the sealing, i.e. the coupling device (at the inlet) may be welded to an external tube <NUM> of any dimension for easy installation inside the reactor. A potential commercial use of the invention is membrane sealing for membrane separation and membrane reactors.

Claim 1:
A coupling device (<NUM>) for a tube (<NUM>) having a Palladium-based membrane deposited thereon, the tube for use in separation and purification of hydrogen in a hydrogen separator or reactor, the coupling device having an inlet (<NUM>) for a gas and configured to couple said tube to the inlet so that the gas can be supplied via the inlet into the tube, the coupling device comprising:
a body part (<NUM>) with a cylindrical opening (<NUM>) for receiving the tube, the opening being arranged to receive gas flow to the inlet; and
a nut (<NUM>), wherein the body part and the nut being configured such that the nut can be screwed onto the body part at the opening;
the coupling device further having a stack (<NUM>) of at least two sealing rings (<NUM>, <NUM>) provided between an end portion (<NUM>) of the body part surrounding the opening and an axial end portion (<NUM>) of the nut,
wherein the body part, the nut and the stack of sealing rings are configured such that the tube extends through the axial end portion of the nut, through the stack of sealing rings and into the opening such that, in use, the stack of sealing rings is compressed in an axial direction (<NUM>) of the stack as a result of screwing the nut onto the body part so that the sealing rings sealingly engage a circumferential surface (<NUM>) of the tube, wherein a sealing ring (<NUM>) of the stack (<NUM>) of sealing rings (<NUM>, <NUM>), which sealing ring (<NUM>) in use contacts the end portion (<NUM>) of the body part (<NUM>) surrounding the opening (<NUM>), is a square or rectangular shaped O-ring
characterised in that the square or rectangular shaped O-ring has an axially protruding tapered ridge (<NUM>), preferably a circumferential ridge, facing the end portion (<NUM>) of the body part, wherein the end portion of the body part has a correspondingly tapered or chamfered portion (<NUM>) for receiving therein the ridge (<NUM>).