Effect of cathode sheet resistance on segmented-in-series SOFC power density

Segmented-in-series solid oxide fuel cells with relatively short cell lengths of 1.4 mm were fabricated with varying LSM cathode current collector thicknesses. Increasing the LSM thickness from 11 to 91 μm yielded a factor of 2–3 area-specific resistance decrease and a similar power density increase. The maximum power density measured at 800 °C was 0.53 W cm⁻² calculated based on total array area (including interconnect), and 0.9 W cm⁻² calculated based on active cell area. A segmented-in-series electrical model was used to quantitatively explain the results based on the decreased cathode sheet resistance. The model also showed that the cell lengths were near optimal for maximizing the power density of these cells.     

Three-dimensional anode engineering for the direct methanol fuel cell

Catalyzed graphite felt three-dimensional anodes were investigated in direct methanol fuel cells (DMFCs) operated with sulfuric acid supporting electrolyte. With a conventional serpentine channel flow field the preferred anode thickness was 100 μm, while a novel flow-by anode showed the best performance with a thickness of 200-300 μm. The effects of altering the methanol concentration, anolyte flow rate and operating temperature on the fuel cell superficial power density were studied by full (2³ + 1) factorial experiments on a cell with anode area of 5 cm² and excess oxidant O₂ at 200 kPa(abs). For operation in the flow-by mode with 2 M methanol at 2 cm³ min⁻¹ and 353 K the peak power density was 2380 W m⁻² with a PtRuMo anode catalyst, while a PtRu catalyst yielded 2240 W m⁻² under the same conditions.     

Design,fabrication and performance analysis of a 200 W PEM fuel cell short stack

A PEM fuel cell short stack of 200 W capacity, with an active area of 100 cm² has been designed and fabricated in-house. The status of unit cell performance was 0.55 W cm⁻². Based on the unit cell technology, a short stack has been developed. The proper design of uniform flow distribution, cooling plate and compressed end plate were important to achieve the best performance of the short stack. The performance of four cells stack was analyzed in static and dynamic modes. In the static mode of polarization curve, the stack has peak power density of 0.55 W cm⁻² (220 W) at 0.5 V per cell, when the voltage was scanning from low to high voltage (1.5–3.5 V), and resulted in minimum water flooding inside the stack. In this study a series of dynamic loadings were tested to simulate the vehicle acceleration. The fuel cell performances respond to dynamic loading influenced by the hydrogen/air stoichiometric, back pressure, and dynamic-loading time. It was needed high hydrogen stoichiometric and back pressure to maintain high dynamic performance. In the long-time stable power testing, the stack was difficult to maintain at high performance, due to the water flooding at high output power. An adjusting cathode back-pressure method for purging water was proposed to prevent the water flooding at flow channels and maintain the stable output power at 170 W (0.42 W cm⁻²).     

Ageing of anode-supported solid oxide fuel cell stacks including thermal cycling,and expansion behaviour of MgO–NiO anodes

This paper reports on medium term tests of anode-supported five-cell short stacks, as well as on some separate anode development. Two stacks were operated under steady-state conditions: one with unprotected metal interconnects, H₂ fuel and 0.35 A cm⁻² (40% fuel utilisation) polarisation current showed an average cell voltage degradation of 56 mV per 1000 h for 2750 h; one with coated metal interconnects, synthetic reformate fuel and 0.5 A cm⁻² (60% fuel utilisation) polarisation current showed an averaged cell voltage degradation slope of 6.6 mV per 1000 h for 800 h before a power cut prematurely interrupted the test. A third stack was subjected to 13 complete thermal cycles over 1000 h, average cell voltage degradation was evaluated to −2 mV per cycle for operation at 0.3 A cm⁻², open circuit voltage (OCV) remained stable, whereas area specific resistance (ASR) increase amounted on average to 0.008 Ω cm² per cycle.     

Solid oxide fuel cells with bi-layered electrolyte structure

In this work, we have developed solid oxide fuel cells with a bi-layered electrolyte of 2 μm SSZ and 4 μm SDC using tape casting, screen printing, and co-firing processes. The cell reached power densities of 0.54 W cm⁻² at 650 °C and 0.85 W cm⁻² at 700 °C, with open circuit voltage (OCV) values larger than 1.02 V. The electrical leaking between anode and cathode through an SDC electrolyte has been blocked in the bi-layered electrolyte structure. However, both the electrolyte resistance (R_el) and electrode polarization resistance (R_p,a+c) increased in comparison to cells with single-layered SDC electrolytes. The formation of a solid solution of (Ce, Zr)O_2−x during sintering process and the flaws in the bi-layered electrolyte structure seem to be the main causes for the increase in the R_el value (0.32 Ω cm²) at 650 °C, which is almost one order of magnitude higher than the calculated value.     

Silver infiltrated La0.6Sr0.4Co0.2Fe0.8O3 cathodes for intermediate temperature solid oxide fuel cells

Porous La_0.6Sr_0.4Co_0.2Fe_0.8O₃ (LSCF) electrodes on anode support cells were infiltrated with AgNO₃ solutions in citric acid and ethylene glycol. Two types of solid oxide fuel cells with the LSCF–Ag cathode, Ni–YSZ/YSZ/LSCF–Ag and Ni–Ce_0.9Gd_0.1O_1.95(GDC)/GDC/LSCF–Ag, were examined in a temperature range 530–730 °C under air oxidant and moist hydrogen fuel. The infiltration of about 18 wt.% Ag fine particles into LSCF resulted in the enhancement of the power density of about 50%. The maximum power density of Ni–YSZ/YSZ/LSCF was enhanced from 0.16 W cm⁻² to 0.25 W cm⁻² at 630 °C by infiltration of AgNO₃. No significant degradation of out-put power was observed for 150 h at 0.7 V and 700 °C. The Ni–GDC/GDC/LSCF–Ag cell showed the maximum power density of 0.415 W cm⁻² at 530 °C.     

A miniature microbial fuel cell operating with an aerobic anode chamber

A miniature microbial fuel cell (mini-MFC) is described that utilizes an aerobic culture of Shewanella oneidensis DSP10 as the active electrochemical species in the anode chamber. We find that the maximum aerobic mini-MFC power without the addition of exogenous mediators was 0.40 mW, a 33% decrease when compared with an anaerobic DSP10 culture (0.6 mW) operating in the mini-MFC. This decrease is most likely due to the presence of dissolved oxygen in the anode chamber that scavenges electrons to form water, thereby reducing the number of electrons donated to the anode. Aerobic power and current density at maximum power using the true surface area of the anode (611 cm²) were calculated to be 6.5 mW m⁻² and 13 mA m⁻². The power density rises to 2.0 W m⁻² and 330 W m⁻³ when calculated using the cross-sectional area and volume of the device (2 cm², 1.2 cm³). The Coulombic efficiency was also reduced from 11 to 5% when using the aerobic versus anaerobic culture. Similar results were found when the external mediator anthraquinone-2,6-disulfonate (AQDS) was added to the aerobic culture, resulting in a maximum power of 0.54 mW, a 37% drop in power when compared to the anaerobic mediated system.     

Laccase electrodes based on the combination of single-walled carbon nanotubes and redox layered double hydroxides: Towards the development of biocathode for biofuel cells

Single-walled carbon nanotubes (SWCNT) were combined with layered double hydroxides (LDH) intercalated with 2,2′-azino-bis(3-ethylbenzothiazoline-6-sulfonate) diammonium salt [ZnCr-ABTS] to entrap and electrically connect laccase enzyme. The resulting laccase electrodes exhibited an electro-enzymatic activity for O₂ reduction. To improve this electrocatalytic activity, varying SWCNT quantities and loading methods were tested to optimize the configuration of the laccase electrodes. Furthermore, the resulting bioelectrode was successfully used as a biocathode for the elaboration of a membrane-less glucose/air biofuel cell. In 0.1 M phosphate buffer (PBS) of pH 6.0, containing glucose (5 mM) under ambient conditions, the assembled biofuel cell yielded a maximum power density of 18 μW cm⁻² at a cell voltage of 0.3 V whereas this power decreased to 8.3 μW cm⁻² for a biofuel cell based on the identical biocathode setup without SWCNT.     

A direct borohydride fuel cell employing Prussian Blue as mediated electron-transfer hydrogen peroxide reduction catalyst

A direct borohydride-hydrogen peroxide fuel cell employing carbon-supported Prussian Blue (PB) as mediated electron-transfer cathode catalyst is reported. While operating at 30 °C, the direct borohydride-hydrogen peroxide fuel cell employing carbon-supported PB cathode catalyst shows superior performance with the maximum output power density of 68 mW cm⁻² at an operating voltage of 1.1 V compared to direct borohydride-hydrogen peroxide fuel cell employing the conventional gold-based cathode with the maximum output power density of 47 mW cm⁻² at an operating voltage of 0.7 V. X-ray diffraction (XRD), Scanning Electron Microscopy (SEM), and Energy Dispersive X-ray Analysis (EDAX) suggest that anchoring of Cetyl-Trimethyl Ammonium Bromide (CTAB) as a surfactant moiety on carbon-supported PB affects the catalyst morphology. Polarization studies on direct borohydride-hydrogen peroxide fuel cell with carbon-supported CTAB-anchored PB cathode exhibit better performance with the maximum output power density of 50 mW cm⁻² at an operating voltage of 1 V than the direct borohydride-hydrogen peroxide fuel cell with carbon-supported Prussian Blue without CTAB with the maximum output power density of 29 mW cm⁻² at an operating voltage of 1 V.     

Effects of anode surface modification on the performance of low temperature SOFCs

An anode functional layer (AFL, ∼5 μm) for improving the cell performance was fabricated by the slurry spin coating method on the porous surface of an anode substrate. The effects of the AFL on the anode/electrolyte interfacial morphology and the Sm_0.2Ce_0.8O_1.9 (SDC) film deposition process were evaluated. And the electrochemical characteristics of the cells with and without the AFL were tested for comparison. With the AFL layer, the cell performance was greatly improved and the maximum power density was increased from 0.733 to 0.884 W cm⁻² at 600 °C and from 1.085 to 1.213 W cm⁻² at 650 °C. The systematical analysis indicated that the AFL could effectively reduce the anode polarization loss by increasing the three-phase boundary (TPB) length.     

Cathode contact optimization and performance evaluation of intermediate temperature-operating solid oxide fuel cell stacks based on anode-supported planar cells with LaNi0.6Fe0.4O3 cathode

This paper reports the development of intermediate temperature-operating solid oxide fuel cell stacks using anode-supported planar cells with LaNi_0.6Fe_0.4O₃ (LNF)cathode. We developed metallic separators with radial gas flow channels and an anode seal structure. To achieve good power-generating characteristics, we propose two cathode contact methods. According to a performance evaluation at 800 °C, power density of 0.5 W cm⁻² is obtained at the current density of 1.0 A cm⁻² when operating with a sufficient fuel amount, and power conversion efficiency of over 50% LHV is obtained at the current density of more than 0.2 A cm⁻² when operating at a high fuel utilization rate.     

Surface modification and performance of inexpensive Fe-based bipolar plates for proton exchange membrane fuel cells

A reforming pack chromization with rolling pretreatment process is utilized to develop inexpensive and high-performance Fe-based metal bipolar plates (SS 420, SS 430, and SS 316 stainless steels) for PEMFC systems. Rolling process is previously performed to reduce the chromizing temperature and generate a coating possessing excellent conductivity and corrosion resistance on the steels during chromization. The power efficiencies of rolled-chromized and simple chromized bipolar plates are compared with graphite bipolar plates employed in PEMFCs. The results show that the rolled-chromized bipolar plates have a corrosion current (I_corr) of 7.87 × 10⁻⁸ A cm⁻² and an interfacial contact resistance of 9.7 mΩ cm². Moreover, the power density of the single cell assembled with rolled-chromized bipolar plates is 0.46 W cm⁻², which is very close to that of graphite (0.50 W cm⁻²), in the tested conditions of this study.     

Planar air-breathing micro-direct methanol fuel cell stacks based on micro-electronic–mechanical-system technology

To meet the demands for high power micro-electronic devices, two silicon-based micro-direct methanol fuel cell (μDMFC) stacks consisting of six individual cells with two different anode flow fields were designed, fabricated and evaluated. Micro-electronic–mechanical-system (MEMS) technology was used to fabricate both flow field plate and fuel distribution plate on the silicon wafer. Experimental results show that either an individual cell or a stack with double serpentine-type flow fields presents better cell performance than those with pin-type flow fields. A μDMFC stack with double serpentine-type flow fields generates a peak output power of ca. 151 mW at a working voltage of 1.5 V, corresponding to an average power density of ca. 17.5 mW cm⁻², which is ca. 20.7% higher than that with pin-type flow fields. The volume and weight of the stacks are only 5.3 cm³ and 10.7 g, respectively. Such small stacks could be used as power sources for micro-electronic devices.     

Laser-printed thick-film electrodes for solid-state rechargeable Li-ion microbatteries

Laser-printed thick-film electrodes (LiCoO₂ cathode and carbon anode) are deposited onto metallic current collectors for fabricating Li-ion microbatteries. These microbatteries demonstrate a significantly higher discharge capacity, power and energy densities than those made by sputter-deposited thin-film techniques. This increased performance is attributed to the porous structure of the laser-printed electrodes, which allows improved ionic and electronic transport through the thick electrodes (∼100 μm) without a significant increase in internal resistance. These laser-printed electrodes are separated by a laser-cut porous membrane impregnated with a gel polymer electrolyte (GPE) in order to build mm-size scale solid-state rechargeable Li-ion microbatteries (LiCoO₂/GPE/carbon). The resulting packaged microbatteries exhibit a power density of ∼38 mW cm⁻² with a discharge capacity of ∼102 μAh cm⁻² at a high discharge rate of 10 mA cm⁻². The laser-printed microbatteries also exhibit discharge capacities in excess of 2500 μAh cm⁻² at a current density of 100 μA cm⁻². This is over an order of magnitude higher than that observed for sputter-deposited thin-film microbatteries (∼160 μAh cm⁻²).     

Electrochemical capacitance of NiO/Ru0.35V0.65O2 asymmetric electrochemical capacitor

A designed asymmetric hybrid electrochemical capacitor was presented where NiO and Ru_0.35V_0.65O₂ as the positive and negative electrode, respectively, both stored charge through reversible faradic pseudocapacitive reactions of the anions (OH⁻) with electroactive materials. And the two electrodes had been individually tested in 1 M KOH aqueous electrolyte to define the adequate balance of the active materials in the hybrid system as well as the working voltage of the capacitor based on them. The electrochemical tests demonstrated that the maximum specific capacitance and energy density of the asymmetric hybrid electrochemical capacitor were 102.6 F g⁻¹ and 41.2 Wh kg⁻¹, respectively, delivered at a current density of 7.5 A cm⁻². And the specific energy density decreased to 23.0 Wh kg⁻¹ when the specific power density increased up to 1416.7 W kg⁻¹. The hybrid electrochemical capacitor also exhibited a good electrochemical stability with 83.5% of the initial capacitance over consecutive 1500 cycle numbers.     

Flexible thermoelectric generator for ambient assisted living wearable biometric sensors

In this work we proposed design, fabrication and functional characterization of a very low cost energy autonomous, maintenance free, flexible and wearable micro thermoelectric generator (μTEG), finalized to power very low consumption electronics ambient assisted living (AAL) applications. The prototype, integrating an array of 100 thin films thermocouples of Sb₂Te₃ and Bi₂Te₃, generates, at 40 °C, an open circuit output voltage of 430 mV and an electrical output power up to 32 nW with matched load. In real operation conditions of prototype, which are believed to be very close to a thermal gradient of 15 °C, the device generates an open circuit output voltage of about 160 mV, with an electrical output power up to 4.18 nW.In the first part of work, deposition investigation Sb₂Te₃ and Bi₂Te₃ thin films alloys on Kapton HN polyimide foil by RF magnetron co-sputtering technique is discussed. Deposition parameters have been optimized to gain perfect stoichiometric ratio and high thermoelectric power factor; fabricated thermogenerator has been tested at low gradient conditioned to evaluate applications like human skin wearable power generator for ambient assisted living applications.     

Low temperature solid oxide fuel cells with pulsed laser deposited bi-layer electrolyte

Solid oxide fuel cells (SOFC) using a pulsed laser deposited bi-layer electrolyte have been successfully fabricated and have shown very good performance at low operating temperatures. The cell reaches power densities of 0.5 W cm⁻² at 550 °C and 0.9 W cm⁻² at 600 °C, with open circuit voltage (OCV) values larger than 1.04 V. The bi-layer electrolyte contains a 6–7 μm thick samarium-doped ceria (SDC) layer deposited over a ∼1 μm thick scandium-stabilized zirconia (ScSZ) layer. The electrical leaking between the anode and cathode through the SDC electrolyte, which due to the reduction of Ce⁴⁺ to Ce³⁺ in reducing environment when using a single layer SDC electrolyte, has been eliminated by adopting the bi-layer electrolyte concept. Both ScSZ and SDC layers in the bi-layer electrolyte prepared by the pulsed laser deposition (PLD) technique are the highly conductive cubic phases. Poor conductive (Zr, Ce)O₂-based solid solutions or β-phase ScSZ were not found in the bi-layer electrolyte prepared by the PLD due to low processing temperatures of the technique. Excellent reliability and flexibility of the PLD technique makes it a very promising technique for the fabrication of thin electrolyte layer for SOFCs operating at reduced temperatures.     

Passive direct methanol fuel cells for portable electronic devices

Due to the increasing demand for electricity, clean, renewable energy resources must be developed. Thus, the objective of the present study was to develop a passive direct methanol fuel cell (DMFC) for portable electronic devices. The power output of six dual DMFCs connected in series with an active area of 4 cm² was approximately 600 mW, and the power density of the DMFCs was 25 mW cm⁻². The DMFCs were evaluated as a power source for mobile phone chargers and media players. The results indicated that the open circuit voltage of the DMFC was between 6.0 V and 6.5 V, and the voltage under operating conditions was 4.0 V. The fuel cell was tested on a variety of cell phone chargers, media players and PDAs. The cost of energy consumption by the proposed DMFC was estimated to be USD 20 W⁻¹, and the cost of methanol is USD 4 kW h. Alternatively, the local conventional electricity tariff is USD 2 kW h. However, for the large-scale production of electronic devices, the cost of methanol will be significantly lower. Moreover, the electricity tariff is expected to increase due to the constraints of fossil fuel resources and pollution. As a result, DMFCs will become competitive with conventional power sources.     

Performance of anode-supported solid oxide fuel cell using novel ceria electrolyte

The potential of a novel co-doped ceria material Sm_0.075Nd_0.075Ce_0.85O_2−δ as an electrolyte was investigated under fuel cell operating conditions. Conventional colloidal processing was used to deposit a dense layer of Sm_0.075Nd_0.075Ce_0.85O_2−δ (thickness 10 μm) over a porous Ni-gadolinia doped ceria anode. The current-voltage performance of the cell was measured at intermediate temperatures with 90 cm³ min⁻¹ of air and wet hydrogen flowing on cathode and anode sides, respectively. At 650 °C, the maximum power density of the cell reached an exceptionally high value of 1.43 W cm⁻², with an area specific resistance of 0.105 Ω cm². Impedance measurements show that the power density decrease with decrease in temperature is mainly due to the increase in electrode resistance. The results confirm that Sm_0.075Nd_0.075Ce_0.85O_2−δ is a promising alternative electrolyte for intermediate temperature solid oxide fuel cells.     

A microfabricated low cost enzyme-free glucose fuel cell for powering low-power implantable devices

In the past decade the scientific community has showed considerable interest in the development of implantable medical devices such as muscle stimulators, neuroprosthetic devices, and biosensors. Those devices have low power requirements and can potentially be operated through fuel cells using reactants present in the body such as glucose and oxygen instead of non-rechargeable lithium batteries. In this paper, we present a thin, enzyme-free fuel cell with high current density and good stability at a current density of 10 μA cm⁻². A non-enzymatic approach is preferred because of higher long term stability. The fuel cell uses a stacked electrode design in order to achieve glucose and oxygen separation. An important characteristic of the fuel cell is that it has no membrane separating the electrodes, which results in low ohmic losses and small fuel cell volume. In addition, it uses a porous carbon paper support for the anodic catalyst layer which reduces the amount of platinum or other noble metal catalysts required for fabricating high surface area electrodes with good reactivity. The peak power output of the fuel cell is approximately 2 μW cm⁻² and has a sustainable power density of 1.5 μW cm⁻² at 10 μA cm⁻². An analysis on the effects of electrode thickness and inter electrode gap on the maximum power output of the fuel cell is also performed.