The present invention relates to a composite gas separation module and to
methods for fabricating a composite gas separation module. The present
invention also relates to methods for selectively separating hydrogen gas
from a hydrogen gas-containing gaseous stream. In one embodiment, the
composite gas separation module includes a porous metal substrate; an
intermediate porous metal layer, wherein the intermediate porous metal
layer overlies the porous metal substrate; and a dense hydrogen-selective
membrane, wherein the dense hydrogen-selective membrane overlies the
intermediate porous metal layer. The intermediate porous metal layer can
include palladium and a Group IB metal. For example, the intermediate
porous metal layer can contain alternating layers of palladium and a
Group IB metal.