The production of hydrogen from synthesis gas made by gasification of coal is expensive. The separation of hydrogen from synthesis gas is a major cost element in the total process. In this report we describe the results of a program aimed at the development of membranes and membrane modules for the separation and purification of hydrogen from synthesis gas. The performance properties of the developed membranes were used in an economic evaluation of membrane gas separation systems in the coal gasification process. Membranes tested were polyetherimide and a polyamide copolymer. The work began with an examination of the chemical separations required to produce hydrogen from synthesis gas, identification of three specific separations where membranes might be applicable. A range of membrane fabrication techniques and module configurations were investigated to optimize the separation properties of the membrane materials. Parametric data obtained were used to develop the economic comparison of processes incorporating membranes with a base-case system without membranes. The computer calculations for the economic analysis were designed and executed. Finally, we briefly investigated alternative methods of performing the three separations in the production of hydrogen from synthesis gas. The three potential opportunities for membranes in the production of hydrogen from synthesis gas are: (1) separation of hydrogen from nitrogen as the final separation in a air-blown or oxygen-enriched air-blown gasification process, (2) separation of hydrogen from carbon dioxide and hydrogen sulfide to reduce or eliminate the conventional ethanolamine acid gas removal unit, and (3) separation of hydrogen and/or carbon dioxide form carbon monoxide prior to the shift reactor to influence the shift reaction. 28 refs., 54 figs., 40 tabs.