Dense Pd-Ag membranes have shown immense potential to achieve high hydrogen purity required for proton exchange membrane (PEM) fuel cell. However, high hydrogen recovery and flux at lower transmembrane partial pressure is still a concern. In current study self supported dense Pd-Ag membranes were used to study the hydrogen recovery in a multi pass membrane separator. Performance of a single and four collective membranes are tested in a single (without baffle) and multi-pass (with longitudinal baffles) membrane separator. Further, array of membrane configurations were tested experimentally by using longitudinal baffles and placing membranes at different locations. The hydrogen recovery for each configuration was measured experimentally. Experiments were performed using binary gas mixture 50H(2):50N(2) (v/v) at 3 bar pressure, 673 K temperature and gas-hourly space velocity (GHSV) 43 h(-1). The best assembly was further tested with typical methanol reformate gas composition by using simulated gas mixture of 50H(2):30N(2):18CO(2):2CO (v/v) at same operating condition. Numerical simulations were performed by using commercial software ANSYS 14.5 to understand the flow dynamics inside the separator with and without baffle. The results demonstrate that a multi-pass membrane separator enables to control hydrogen partial pressure radially along the length of reactor. This resulted in 33% enhancement in hydrogen recovery with multi-pass in comparison to single pass membrane separator. (C) 2018 Hydrogen Energy Publications LLC. Published by Elsevier Ltd. All rights reserved.