Paper‐Fibres Used as a Pore‐Former for Anode Substrate of Solid Oxide Fuel Cell

Paper‐fibres are studied for use as a pore‐former to produce gas channels in the anode substrates of solid oxide fuel cells (SOFCs). These fibres produce cylindrical pores within the anode substrate, which are different from the pores formed by the conventional pore‐formers such as wheat flour and graphite. The cylindrical pores make it easier to connect each other to form continuous pathways for rapid gas diffusion. Paper‐fibres can create more open porosity than the same amount of flour. The application of the paper‐fibres significantly improves the cell performance by enhancing the gas diffusion process. The anode‐supported YSZ film cells with 5 wt.‐% and 10 wt.‐% paper‐fibres exhibit maximum power densities of 0.72 and 1.06 W cm^–2, respectively, using hydrogen as fuel and ambient air as oxidant at 800 °C.     

Characterisation of Ni–YSZ‐Cermets with Respect to Redox Stability

In anode‐supported solid oxide fuel cells (SOFCs), air break‐in on the anode side can result in reoxidation of metallic nickel. The volume expansion caused by Ni oxidation generates stresses within the substrate, the anode and the electrolyte. Those stresses exceed the stability of the components, potentially promoting crack growth. Therefore, either the SOFC degrades continuously after each redox‐cycle or the membrane electrode assembly (MEA) fails completely if the electrolyte cracks. The influence of several reoxidation parameters on the mechanical integrity of Ni–YSZ‐anodes after reoxidation was investigated using different types of samples. All samples were SFEs (substrate–functional layer–electrolytes), consisting of Ni–YSZ‐substrate, Ni–YSZ‐anode and YSZ‐electrolyte. Investigations were carried out on freestanding SFEs and SFEs attached to steel plates (Crofer22APU, Thyssen Krupp V. D. M., Material Data Sheet No. 4046, Edition of December 2006) with a glass sealing. The results show a big influence of the degree of oxidation, homogeneity of oxidation, the operating temperature and the incident flow on the behaviour and the mechanical integrity of the reoxidised SFEs. The time of oxidation and the gas flow rate were influencing parameters, whereas the influence of the porosity was insignificant. The behaviour of the SFEs upon reoxidation also changes dramatically when comparing freestanding samples with attached samples.     

Electrochemical performance and microstructure characterization of nickel yttrium‐stabilized zirconia anode

A nickel and yttrium‐stabilized zirconia (Ni‐YSZ) composite is one of the most commonly used anode materials in solid oxide fuel cells (SOFCs). One of the drawbacks of the Ni‐YSZ anode is its susceptibility to deactivation due to the formation of carbonaceous species when hydrocarbons are used as fuel supplies. We therefore initiated an electrochemical study of the influence of methane (CH₄) on the performance of Ni‐YSZ anodes by examining the kinetics of the oxidation of CH₄ and H₂ over operating temperatures of 600–800°C. Anode performance deterioration was then correlated with the degree of carbonization observed on the anode using ex‐situ X‐ray powder diffraction and scanning electron microscopy techniques. Results showed that carbonaceous species led to a significant deactivation of Ni‐YSZ anode toward methane oxidation. © 2009 American Institute of Chemical Engineers AIChE J, 2010     

Catalytic Influence of Oxide Component in Ni‐Based Cermet Anodes for Ammonia‐Fueled Solid Oxide Fuel Cells

Recently, the promising prospect of ammonia as a hydrogen carrier for solid oxide fuel cells (SOFCs) has attracted significant interests. In this work, the effects of temperature, fuel content, and total flow rate of anode gas on the performance of Ni/yttria‐stabilized zirconia (Ni/YSZ) anode for ammonia‐fueled SOFCs were investigated. Based on obtained results, the utilization route of ammonia on Ni/YSZ anode was discussed; the results of electrochemical experiments were related with the catalytic decomposition bahavior of ammonia over Ni/YSZ. Moreover, the catalytic activity for ammonia decomposition and anode performance of Ni/samarium‐doped ceria (Ni/SDC) and Ni/yttrium‐doped barium cerate (Ni/BCY) were also investigated. Among these anode materials, Ni/BCY exhibited the highest ammonia decomposition activity and anode performance for ammonia‐fueled SOFCs at intermediate temperatures.     

Synthesis of Highly Porous Yttria-Stabilized Zirconia by Tape-Casting Methods

Porous ceramics of Y₂O₃-stabilized ZrO₂ (YSZ) were prepared by tape-casting methods using both pyrolyzable pore formers and NiO followed by acid leaching. The porosity of YSZ wafers increased in a regular manner with the mass of graphite or polymethyl methacrylate (PMMA) to between 60% and 75% porosity. SEM indicated that the shape of the pores in the final ceramic was related to the shape of the pore formers, so that the pore size and microstructure of YSZ wafers could be controlled by the choice of pore former. Dilatometry measurements showed that measurable shrinkage started at 1300 K, and a total shrinkage of 26% was observed, independent of the amount or type of pore former used. Temperature-programmed oxidation (TPO) measurements on the green tapes demonstrated that the binders and dispersants were combusted between 550 and 750 K, that PMMA decomposed to methyl methacrylate between 500 and 700 K, and that graphite combusted above 900 K. The porosity of YSZ ceramics prepared by acid leaching of nickel from NiO–YSZ, with 50 wt% NiO, was studied as a function of NiO and YSZ particle size. Significant changes in pore dimension were found when NiO particle size was changed.     

Electrochemical Performance of a Ni and YSZ Composite Synthesised by Ultrasonic Spray Pyrolysis as an Anode for SOFCs

The electrochemical performance of an anode material for a solid oxide fuel cell (SOFC) depends highly on microstructure in addition to composition. In this study, a NiO–yttria‐stabilised zirconia (NiO–YSZ) composite with a highly dispersed microstructure and large pore volume/surface area has been synthesised by ultrasonic spray pyrolysis (USP) and its electrochemical characteristics has been investigated. For comparison, the electrochemical performance of a conventional NiO–YSZ is also evaluated. The power density of the zirconia electrolyte‐supported SOFC with the synthesised anode is ∼392 mW cm^–2 at 900 °C and that of the SOFC with the conventional NiO–YSZ anode is ∼315 mW cm^–2. The improvement is ∼24%. This result demonstrates that the synthesised NiO–YSZ is a potential alternative anode material for SOFCs fabricated with a zirconia solid electrolyte.     

Micro‐Scale Modeling of a Functionally Graded Ni‐YSZ Anode

A mathematical model was developed to investigate the coupled transport and electrochemical reactions in a nickel‐yttrial‐stablized zirconia (Ni‐YSZ) anode for use in solid oxide fuel cells (SOFCs). The modeling results were consistent with experimental data from the literature. Comparison between conventional non‐graded (uniform random composites) and two types of functionally graded electrodes (FGE), namely particle size graded and porosity graded SOFC anodes were conducted to evaluate the potential of FGE for SOFC. Improved performance of both types of FGE was observed due to reduced mass transport resistance and increased volumetric reactive surface area close to the electrode‐electrolyte interface. It was found that the particle size graded SOFC anode showed the best performance. This paper demonstrates that the SOFC performance could be enhanced by modifying the microstructures of the electrodes. The results presented in this paper provide a better understanding of the working mechanisms of SOFC electrodes and could serve as an important reference for design optimizations.     

Infiltration of SOFC Stacks: Evaluation of the Electrochemical Performance Enhancement and the Underlying Changes in the Microstructure

Experimental SOFC stacks with 10 SOFCs (LSM‐YSZ/YSZ/Ni‐YSZ) were infiltrated with CGO and Ni‐CGO on the air and fuel side, respectively in an attempt to counter degradation and improve the output. The electrochemical performance of each cell was characterized (i) before infiltration, (ii) after infiltration on the cathode side, and (iii) after the infiltration of the anode side. A significant performance enhancement was observed after the infiltration with CGO on the cathode, while the infiltration of the anode side with Ni‐CGO had no significant effect on the electrochemical performance. After testing the cells were characterized by SEM and TEM/EELS. A thin layer of CGO nanoparticles around the LSM‐YSZ back bone structure was found after infiltration. On the anode side nano sized Ni particles were found embedded in a CGO layer formed around the Ni‐YSZ structure. EELS analysis showed that the oxidation state of the Ce ions is identical on the air and the fuel side.     

Electronic Current Distribution Calculation for a Ni‐YSZ Solid Oxide Fuel Cell Anode

A simulation of a nickel‐yttrium stabilized zirconium oxide (Ni‐YSZ) solid oxide fuel cell cermet anode was used to determine the electronic current distribution within the percolating networks of nickel particles distributed in the electrode. The anode is simulated via a Monte–Carlo percolation model and current distribution is calculated via a relaxation algorithm. Nickel particle current densities are reported as a ratio to the total anode current density allowing results to be applied to any anode current density. Calculated current distributions were drastically affected by the volume percent of nickel as well as anode porosity. Experiments were performed to determine failure current densities of thin nickel wires to establish the relationship between critical current densities and surface area or volume of the wires. Both reducing and oxidizing environments were used for these measurements over a temperature range up to 800 °C.     

The Effect of H2S on the Performance of SOFCs using Methane Containing Fuel

In recent years, the interest for using biogas derived from biomass as fuel in solid oxide fuel cells (SOFCs) has increased. To maximise the biogas to electrical energy output, it is important to study the effects of the main biogas components (CH₄ and CO₂), minor ones and traces (e.g. H₂S) on performance and durability of the SOFC. Single anode‐supported SOFCs with Ni–Yttria‐Stabilised‐Zirconia (YSZ) anodes, YSZ electrolytes and lanthanum‐strontium‐manganite (LSM)–YSZ cathodes have been tested with a CH₄–H₂O–H₂ fuel mixture at open circuit voltage (OCV) and 1 A cm^–2 current load (850 °C). The cell performance was monitored with electric measurements and impedance spectroscopy. At OCV 2–24 ppm H₂S were added to the fuel in 24 h intervals. The reforming activity of the Ni‐containing anode decreased rapidly when H₂S was added to the fuel. This ultimately resulted in a lower production of fuel (H₂ and CO) from CH₄. Applying 1 A cm^–2 current load, a maximum concentration of 7 ppm H₂S was acceptable for a 24 h period.     

Improvement of Ni-Cermet performance of protonic ceramic fuel cells by catalyst

Generally, the NiO composite anode becomes porous after reduction. To infiltrate additional catalysts such as Pd into the NiO-composite anode before reducing NiO to Ni, a porous NiO composite anode for protonic ceramic fuel cells (PCFCs) was fabricated in this study. The porous NiO composite was fabricated by adding graphite as a pore former along with CuO as a sintering agent. The addition of graphite increased the porosity of the NiO composite anode but resulted in poor sinterability, which was addressed by adding CuO as a sintering agent to the NiO composite anode. The Pd catalyst was added to the NiO-composite anode before reducing NiO to Ni. The composite anode for PCFC with three components, namely Ni, protonic ceramics, and a Pd catalyst, was obtained by reducing NiO to Ni during the measurement. The addition of the Pd catalyst improved the anode performance in methane fuel and hydrogen fuel by enhancing the catalytic activity for the electrochemical reaction on the surface.     

Influences of feedstock and plasma spraying parameters on the fabrication of tubular solid oxide fuel cell anodes

This study developed a tubular solid oxide fuel cell (SOFC) anode support layer via atmospheric plasma spraying, which is considered one of the most promising methods for producing SOFCs because of its faster deposition rate and lower cost compared with other film formation processes. Plasma spraying can replace the traditional use of extrusion technology to manufacture the anode base tube, eliminating the need for high-temperature sintering steps. In this study, commercially available powders were used to make the anode of a tubular SOFC from NiO/yttria-stabilized zirconia (YSZ) powder, and Na₂CO₃ and polymethyl methacrylate were tested as pore-forming agents. The anode composite powder was sprayed on the graphite base pipe, and the final product was changed by altering the spraying parameters and anode powder ratio. The direct current (DC) resistance measurements showed that the conductivity of the Ni/YSZ tubular anode formed with higher power plasma spraying could reach 428.55?S/cm at 800?°C. The experimental results showed that the power and parameters of atmospheric plasma spraying could affect the porosity and electron conductivity of tubular SOFC anodes.     

Direct-methane anode-supported solid oxide fuel cells fabricated by aqueous gel-casting

Direct methane Solid Oxide Fuel Cells (SOFCs) operated under catalytic partial oxidation (CPOX) conditions are investigated, focusing on the processing of the anode support and the anode deactivation caused by carbon deposition. Anode-supported SOFCs based on gadolinium-doped ceria (GDC) electrolyte, and NiO-GDC anode support were fabricated by the gel-casting method. Suitable aqueous slurries formulations of NiO–GDC were prepared, starting NiO-GDC nanocomposite powders, agarose as gelling agent and rice starch as pore former. Electrochemical and mechanical tests evidenced that the support of 550 ± 50 µm thickness and 10 wt% pore former is a good candidate for direct-methane SOFCs. The cells operating under stoichiometric conditions of CPOX reached a performance of 0.64 W·cm^?2 at 650 ºC, a very close value to that measured under humidified hydrogen (0.71 W·cm^?2). The best electrochemical stability of the cell is achieved at a CH₄/O₂ ratio of 2.5, showing no evidence of carbon deposition and reducing nickel re-oxidation significantly.     

Compilation of mechanical properties for the structural analysis of solid oxide fuel cell stacks. Constitutive materials of anode-supported cells

The mechanical failure of one cell is sufficient to lead to the end of service of a solid oxide fuel cell (SOFC) stack. Therefore, there is growing interest in gaining knowledge on the mechanical properties of the cell materials for stress analysis.This study compiles available data from the literature on the mechanical properties of the most common materials used in intermediate-temperature anode-supported cells: nickel and yttria-stabilized zirconia (Ni–YSZ) anodes, YSZ electrolytes, yttria (YDC) or gadolinia-doped ceria (GDC) compatibility layers and lanthanum strontium manganite (LSM) or lanthanum strontium cobalt ferrite (LSCF) cathodes. The properties for the simulation of stresses, i.e. coefficient of thermal expansion (CTE), Young's modulus, Poisson's ratio, creep behaviour and strength are reported, with an emphasis on temperature and porosity dependence and the evolution upon aging or cycling when available. Measurements of our Ni(O)–YSZ anode material includes the CTE (oxidised and reduced state), Young's modulus and strength at room temperature (oxidised and reduced) and 1073 K (oxidised).     

Development of a novel proton conducting fuel cell based on a Ni‐YSZ support

A new proton conducting fuel cell design based on the BZCYYb electrolyte is studied in this research. In high‐performance YSZ‐based SOFCs, the Ni‐YSZ support plays a key role in providing required electrical properties and robust mechanical behavior. In this study, this well‐established Ni‐YSZ support is used to maintain the proton conducting fuel cell integrity. The cell is in a Ni‐YSZ (375 μm support)/Ni‐BZCYYb (20 μm anode functional layer)/BZCYYb (10 μm electrolyte)/LSCF‐BZCYYb (25 μm cathode) configuration. Maximum power density values of 166, 218, and 285 mW/cm² have been obtained at 600°C, 650°C, and 700°C, respectively. AC impedance spectroscopy results show values of 2.17, 1.23, and 0.76 Ω·cm² at these temperatures where the main resistance contributor above 600°C is ohmic resistance. Very fine NiO and YSZ powders were used to achieve a suitable sintering shrinkage which can enhance the electrolyte sintering. During cosintering of the support and BZCYYb electrolyte layers, the higher shrinkage of the support layer led to compressive stress in the electrolyte, thereby enhancing its densification. The promising results of the current study show that a new generation of proton conducting fuel cells based on the chemically and mechanically robust Ni‐YSZ support can be developed which can improve long‐term performance and reduce fabrication costs of proton conducting fuel cells.     

NI/NI‐YSZ Current Collector/Anode Dual Layer Hollow Fibers for Micro‐Tubular Solid Oxide Fuel Cells

A co‐extrusion technique was employed to fabricate a novel dual layer NiO/NiO‐YSZ hollow fiber (HF) precursor which was then co‐sintered at 1,400 °C and reduced at 700 °C to form, respectively, a meshed porous inner Ni current collector and outer Ni‐YSZ anode layers for SOFC applications. The inner thin and highly porous “mesh‐like” pure Ni layer of approximately 50 μm in thickness functions as a current collector in micro‐tubular solid oxide fuel cell (SOFC), aiming at highly efficient current collection with low fuel diffusion resistance, while the thicker outer Ni‐YSZ layer of 260 μm acts as an anode, providing also major mechanical strength to the dual‐layer HF. Achieved morphology consisted of short finger‐like voids originating from the inner lumen of the HF, and a sponge‐like structure filling most of the Ni‐YSZ anode layer, which is considered to be suitable macrostructure for anode SOFC system. The electrical conductivity of the meshed porous inner Ni layer is measured to be 77.5 × 10⁵ S m^–1. This result is significantly higher than previous reported results on single layer Ni‐YSZ HFs, which performs not only as a catalyst for the oxidation reaction, but also as a current collector. These results highlight the advantages of this novel dual‐layer HF design as a new and highly efficient way of collecting current from the lumen of micro‐tubular SOFC.     

Fabrication and Power Densities of Anode‐Supported Solid Oxide Fuel Cells with Different Ni‐YSZ Anode Functional Layer Thicknesses

We investigated an appropriate preparation condition for anode‐supported SOFCs: (La,Sr)MnO₃/cathode functional layer/YSZ/Ni‐YSZ were fabricated with and without a Ni‐YSZ anode functional layer (AFL) via the tape‐casting method, where the AFL thicknesses were controlled from approximately 20 to 80 μm. The warpage depended on the co‐sintering temperature of the electrolyte/AFL/anode‐support half‐cells, indicating that similar shrinkage of the electrolyte/AFL/anode support is significant for lower warpages. The electrical properties of SOFCs with AFLs were compared to those of SOFCs without AFLs. In this regard, the use of an AFL decreased the ohmic and activation polarization resistances due to both the decrease in contact resistance between the electrolyte and the AFL and the increase in three‐phase boundaries. However, the polarization diffusion increased when an AFL was employed, because AFL layers are denser than the anode support. The maximum power densities of samples with AFL were higher than those of SOFCs without AFLs, indicating that the decrease in both ohmic and activation‐polarization resistances is more significant for improving the power densities, as compared to the concentration polarization resistance.     

Micro‐modeling of porous composite anodes for solid oxide fuel cells

A new anode micromodel for solid oxide fuel cells to predict the electrochemical performance of hydrocarbon‐fuelled porous composite anodes with various microstructures is developed. In this model, the random packing sphere method is used to estimate the anode microstructural properties, and the complex interdependency among the multicomponent mass transport, electron and ion transports, and electrochemical and chemical reactions is taken into account. As a case study, a porous Ni–YSZ composite anode operated with biogas fuel is simulated numerically and distributions of the current density, polarization, and mole fraction and rate of flux of the fuel components along the thickness of the anode are determined. The effect of the anode microstructural variables including the porosity, thickness, particle‐size ratio, and particle size and volume fraction of Ni particles on the anode electrochemical performance is also studied. © 2011 American Institute of Chemical Engineers AIChE J, 58: 1893–1906, 2012     

Experimental Study of the Carbon Deposition from CH4 onto the Ni/YSZ Anode of SOFCs

A challenge in the operation of solid oxide fuel cells (SOFCs) with hydrocarbon fuels is the carbon deposition on the nickel/yttria‐stabilized zirconia (Ni/YSZ) anode. The Grabke‐type kinetic model has been proposed for the carbon formation based upon the assumption of elementary steps, which consist of a rate‐limiting dissociative chemisorption step and a stepwise dehydrogenation of the chemisorbed methyl group. This work experimentally studied the carbon formation on a SOFC Ni/YSZ anode exposed to CH₄+H₂ gas mixtures. Experiments were conducted with various gas compositions of CH₄/H₂ and temperatures in the range from 873 K to 1,123 K. The experimental results were used to determine a kinetic model that was applied to the SOFC operating environments. Based on the experimental data, the formula for the carbon formation rate that is dependent on the operating temperature and the gas compositions of CH₄/H₂ was established.     

Development and Fabrication of a New Concept Planar‐tubular Solid Oxide Fuel Cell (PT‐SOFC)

The paper reports a new concept of planar‐tubular solid oxide fuel cell (PT‐SOFC). Emphasis is on the fabrication of the required complex configuration of Ni‐yttria‐stabilised zirconia (YSZ) porous anode support by tert‐butyl alcohol (TBA) based gelcasting, particularly the effects of solid loading, amounts of monomers and dispersant on the rheological behaviour of suspension, the shrinkage of a wet gelcast green body upon drying, and the properties of final sample after sintering at 1350 °C and reduction from NiO‐YSZ to Ni‐YSZ. The results show that the gelcasting is a powerful method for preparation of the required complex configuration anode support. The anode support resulted from an optimised suspension with the solid loading of 25 vol% has uniform microstructure with 37% porosity, bending strength of 44 MPa and conductivity of 300 S cm^—1 at 700 °C, meeting the requirements for an anode support of SOFC. Based on the as‐prepared anode support, PT‐SOFC single cell of Ni‐YSZ/YSZ/LSCF has been fabricated by slurry coating and co‐sintering technique. The cell peak power density reaches 63, 106 and 141 mW cm^—2 at 700, 750 and 800 °C, respectively, using hydrogen as fuel and ambient air as oxidant.