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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

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.

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We claim: 1. A method for fabricating a composite gas separation module, comprising the steps of: a) depositing a preactivated powder over a porous substrate; b) depositing a binder metal in a uniform distribution throughout the preactivated powder; and c) depositing a dense hydrogen-selective memb

We claim: 1. A method for fabricating a composite gas separation module, comprising the steps of: a) depositing a preactivated powder over a porous substrate; b) depositing a binder metal in a uniform distribution throughout the preactivated powder; and c) depositing a dense hydrogen-selective membrane that is not materially breached by regions or points which impair the separation of hydrogen by allowing the passage of an undesired gas to overlie the preactivated powder and binder metal, thereby forming the composite gas separation module. 2. The method of claim 1 wherein the preactivated powder has an average particle diameter ranging from about 0.01 to about 5 microns. 3. The method of claim 1 wherein the preactivated powder is selected from the group consisting of preactivated metal powders, preactivated metal oxide powders, preactivated ceramic powders, preactivated zeolite powders, and combinations thereof. 4. The method of claim 3 wherein the preactivated powder includes preactivated aluminum oxide particles. 5. The method of claim 1 further including the step of surface activating a powder to form the preactivated powder. 6. The method of claim 5 wherein surface activating the powder to form the preactivated powder includes seeding the powder with nuclei of a hydrogen-selective metal. 7. The method of claim 6 wherein the powder is seeded with nuclei of a hydrogen-selective metal using an aqueous activation solution. 8. The method of claim 6 wherein the hydrogen-selective metal is palladium. 9. The method of claim 1 wherein the porous substrate is a porous metal substrate. 10. The method of claim 9 further including the step of oxidizing the surface of the porous metal substrate prior to depositing the preactivated powder. 11. The method of claim 1 further including the step of depositing a powder over the porous substrate prior to depositing the preactivated powder. 12. The method of claim 11 wherein the powder has an average particle diameter ranging from about 1 to about 5 microns. 13. The method of claim 11 wherein the powder includes aluminum oxide particles. 14. The method of claim 11 wherein the powder is deposited from a slurry. 15. The method of claim 1 wherein the preactivated powder is deposited from a slurry. 16. The method of claim 15 wherein the slurry is a water-based slurry. 17. The method of claim 1 wherein depositing a binder metal onto the preactivated powder includes electrolessly plating the binder metal onto the preactivated powder. 18. The method of claim 1 wherein the binder metal is a hydrogen-selective metal or an alloy thereof. 19. The method of claim 1 wherein the binder metal is palladium or an alloy thereof. 20. The method of claim 1 further including the steps of: a) depositing an additional preactivated powder over the deposited preactivated powder and binder metal; and b) depositing an additional binder metal onto the additional preactivated powder; wherein the dense hydrogen-selective membrane is deposited to overlie the additional preactivated powder and the additional binder metal. 21. The method of claim 20 wherein the additional preactivated powder has an average particle size that is smaller than the average particle size of the preactivated powder. 22. The method of claim 20 wherein the preactivated powder has an average particle diameter ranging from about 0.3 to about 3 microns. 23. The method of claim 20 wherein the additional preactivated powder has an average particle diameter ranging from about 0.01 to about 1 micron. 24. The method of claim 1 further including the step of exposing porous substrate anchoring sites following deposition of the preactivated powder over the porous substrate. 25. The method of claim 1 further including the step of exposing porous substrate anchoring sites prior to applying the dense hydrogen-selective membrane. 26. The method of claim 1 further including the step of surface activating the deposited preactivated powder and binder metal prior to depositing the dense gas selective membrane. 27. The method of claim 1 wherein applying the dense hydrogen-selective membrane includes plating palladium, or alloy components thereof, to overlie the preactivated powder and binder metal. 28. The method of claim 1 wherein the dense hydrogen-selective membrane includes palladium alloyed with at least one of the metals selected from the group consisting of copper, silver, gold, platinum, ruthenium, rhodium, yttrium, cerium and indium. 29. The method of claim 1 wherein applying the dense hydrogen selective membrane includes using a method selected from the group consisting of electroless plating, electroplating, thermal deposition, chemical vapor deposition, spray deposition, sputter coating, e-beam evaporation, ion beam evaporation and spray pyrolysis. 30. The method of claim 1 further including the step of treating the composite gas-separation module with hydrogen gas at a temperature of up to about 250° C. 31. The method of claim 30 wherein the pressure of the hydrogen gas ranges up to about 8 bar. 32. The method of claim 30 wherein the composite gas-separation module is treated with hydrogen gas for at least about 1 hour. 33. The method of claim 30 wherein the composite gas-separation module is treated with hydrogen gas for about 1 hour to about 4 hours. 34. A method for fabricating a composite gas separation module, comprising the steps of: a) depositing a preactivated powder over a porous substrate; b) depositing a binder metal onto the preactivated powder; c) depositing a dense gas-selective membrane to overlie the preactivated powder and binder metal, thereby forming the composite gas separation module; and d) exposing porous substrate anchoring sites following the deposition of the preactivated powder over the porous substrate. 35. A method for fabricating a composite gas separation module, comprising the steps of: a) depositing a preactivated powder over a porous substrate; b) depositing a binder metal onto the preactivated powder; c) depositing a dense gas-selective membrane to overlie the preactivated powder and binder metal, thereby forming the composite gas separation module; and d) exposing porous substrate anchoring sites prior to applying the dense gas-selective membrane. 36. A method for fabricating a composite gas separation module, comprising the steps of: a) depositing a preactivated powder over a porous substrate; b) depositing a binder metal onto the preactivated powder; c) depositing a dense gas-selective membrane to overlie the preactivated powder and binder metal by plating palladium, or alloy components thereof, to overlie the preactivated powder and binder metal, thereby forming the composite gas separation module.