Performance of Ni/ScSZ cermet anode modified by coating with Gd0.2Ce0.8O2 for an SOFC running on methane fuel

A Ni/scandia-stabilized zirconia (ScSZ) cermet anode was modified by coating with nano-sized gadolinium-doped ceria (GDC, Gd_0.2Ce_0.8O₂) prepared using a simple combustion process within the pores of the anode for a solid oxide fuel cell (SOFC) running on methane fuel. X-ray diffraction (XRD) and scanning electron microscopy (SEM) were employed in the anode characterizations. Then, the short-term stability for the cells with the Ni/ScSZ and 2.0 wt.%GDC-coated Ni/ScSZ anodes in 97%CH₄/3%H₂O at 700 °C was checked over a relative long period of operation. Open circuit voltages (OCVs) increased from 1.098 to 1.179 V, and power densities increased from 224 to 848 mW cm⁻², as the operating temperature of an SOFC with 2.0 wt.%GDC-coated Ni/ScSZ anode was increased from 700 to 850 °C in humidified methane. The coating of nano-sized Gd_0.2Ce_0.8O₂ particle within the pores of the porous Ni/ScSZ anode significantly improved the performance of anode supported cells. Electrochemical impedance spectra (EIS) illustrated that the cell with Ni/ScSZ anode exhibited far greater impedances than the cell with 2.0 wt.%GDC-coated Ni/ScSZ anode. Introduction of nano-sized GDC particles into the pores of porous Ni/ScSZ anode will result in a substantial increase in the ionic conductivity of the anode and increase the triple phase boundary region expanding the number of sites available for electrochemical activity. No significant degradation in performance has been observed after 84 h of cell testing when 2.0 wt.%GDC-coated Ni/ScSZ anode was exposed to 97%CH₄/3%H₂O at 700 °C. Very little carbon was detected on the anodes, suggesting that carbon deposition was limited during cell operation. Consequently, the GDC coating on the pores of anode made it possible to have good stability for long-term operation due to low carbon deposition.     

Effect of Sm0.2Ce0.8O1.9 on the carbon coking in Ni-based anodes for solid oxide fuel cells running on methane fuel

To directly use hydrocarbon fuel without a reforming process, a new microstructure for Ni/Sm_0.2Ce_0.8O_2−δ (Ni/SDC) anodes, in which the Ni surface of the anode is covered with a porous Sm_0.2Ce_0.8O_2−δ thin film, was investigated as an alternative to conventional Ni/YSZ anodes. The porous SDC thin layer was coated on the pores of the anode using the sol–gel coating method. The cell performance was improved by 20%–25% with the Ni/SDC anode relative to the cell performance with the Ni/YSZ anode due to the high ionic conductivity of the Ni/SDC anode and the increase of electrochemical reaction sites. For the SDC-coated Ni/SDC anode operating with methane fuel, no significant degradation of the cell performance was observed after 180 h due to the surface modification with the SDC film on the Ni surface, which opposes the severe degradation of the cell performance that was observed for the Ni/YSZ anode, which results from carbon deposition by methane cracking. Carbon was hardly detected in the SDC-coated Ni/SDC anode due to the catalytic oxidation of the deposited carbon on the SDC film as well as the electrochemical oxidation of methane in the triple-phase-boundary.     

Solid oxide fuel cells operated by internal partial oxidation reforming of iso-octane

Two types of solid oxide fuel cells (SOFCs), with thin Ce_0.85Sm_0.15O_1.925 (SDC) or 8 mol% Y₂O₃-stabilized ZrO₂ (YSZ) electrolytes, were fabricated and tested with iso-octane/air fuel mixtures. An additional Ru–CeO₂ catalyst layer, placed between the fuel stream and the anode, was needed to obtain a stable output power density without anode coking. Thermodynamic analysis and catalysis experiments showed that H₂ and CO were primary reaction products at ≈750 °C, but that these decreased and H₂O and CO₂ increased as the operating temperature dropped below ≈600 °C. Power densities for YSZ cells were 0.7 W cm⁻² at 0.7 V and 790 °C, and for SDC cells were 0.6 W cm⁻² at 0.6 V and 590 °C. Limiting current behavior was observed due to the relatively low (≈20%) H₂ content in the reformed fuel.     

Operation of ceria-electrolyte solid oxide fuel cells on iso-octane–air fuel mixtures

Reduced-temperature solid oxide fuel cells (SOFCs) – with thin Ce_0.85Sm_0.15O_1.925 (SDC) electrolytes, thick Ni–SDC anode supports, and composite cathodes containing La_0.6Sr_0.4Co_0.2Fe_0.8O₃ (LSCF) and SDC – were fabricated and tested with iso-octane/air fuel mixtures. An additional supported catalyst layer, placed between the fuel stream and the anode, was needed to obtain a stable output power density (e.g. 0.6 W cm⁻² at 590 °C) without anode coking. The Ru-CeO₂ catalyst produced CO₂ and H₂ at temperatures <350 °C, while H₂ and CO became predominant above 500 °C. Power densities were substantially less than for the same cells with H₂ fuel (e.g. 1.0 W cm⁻² at 600 °C), due to the dilute (≈20%) hydrogen in the fuel mixture produced by iso-octane partial oxidation. Electrochemical impedance analysis showed a main arc that represented ≈60% of the total resistance, and that increased substantially upon switching from hydrogen to iso-octane/air.     

Anode-supported solid oxide fuel cell with yttria-stabilized zirconia/gadolinia-doped ceria bilalyer electrolyte prepared by wet ceramic co-sintering process

To protect the ceria electrolyte from reduction at the anode side, a thin film of yttria-stabilized zirconia (YSZ) is introduced as an electronic blocking layer to anode-supported gadolinia-doped ceria (GDC) electrolyte solid oxide fuel cells (SOFCs). Thin films of YSZ/GDC bilayer electrolyte are deposited onto anode substrates using a simple and cost-effective wet ceramic co-sintering process. A single cell, consisting of a YSZ (∼3 μm)/GDC (∼7 μm) bilayer electrolyte, a La_0.8Sr_0.2Co_0.2Fe_0.8O₃–GDC composite cathode and a Ni–YSZ cermet anode is tested in humidified hydrogen and air. The cell exhibited an open-circuit voltage (OCV) of 1.05 V at 800 °C, compared with 0.59 V for a single cell with a 10-μm GDC film but without a YSZ film. This indicates that the electronic conduction through the GDC electrolyte is successfully blocked by the deposited YSZ film. In spite of the desirable OCVs, the present YSZ/GDC bilayer electrolyte cell achieved a relatively low peak power density of 678 mW cm⁻² at 800 °C. This is attributed to severe mass transport limitations in the thick and low-porosity anode substrate at high current densities.     

Performance and stability of SOFC anode fabricated from NiO–YSZ composite particles

Ni–YSZ cermet anodes for solid oxide fuel cells (SOFCs) were fabricated at various sintering temperatures from NiO–YSZ composite particles made by spray pyrolysis (SP) technique. NiO particles covered with fine YSZ (Y₂O₃ stabilized ZrO₂) particles were used as the composite particles, and the initial ratio of Ni and YSZ was set at 75:25 (mol%). As a result, the cermet anode sintered at 1350 °C showed the morphology in which fine YSZ grains were uniformly dispersed on the surface of Ni grain network. Electrical performance such as electrochemical activity and internal resistance of a Ni–YSZ cermet anode changed with sintering temperature. The anode fabricated at 1350 °C showed the highest electrical performance. Especially, a single cell voltage with the Ni–YSZ cermet anode kept very stable for 8000 h at 1000 °C in the SOFC operation condition of H₂—3% H₂O and air. The cermet anode after a long-term test had its initial morphology. It indicates that the Ni–YSZ cermet anode fabricated from NiO–YSZ composite particles is a very promising material for its practical use as SOFCs.     

Dependence of polarization in anode-supported solid oxide fuel cells on various cell parameters

The performance of solid oxide fuel cells (SOFCs) is affected by various polarization losses, namely, ohmic polarization, activation polarization and concentration polarization. Under given operating conditions, these polarization losses are largely dependent on cell materials, electrode microstructures, and cell geometric parameters. Solid oxide fuel cells (SOFC) with yttria-stabilized zirconia (YSZ) electrolyte, Ni–YSZ anode support, Ni–YSZ anode interlayer, strontium doped lanthanum manganate (LSM)–YSZ cathode interlayer, and LSM current collector, were fabricated. The effect of various parameters on cell performance was evaluated. The parameters investigated were: (1) YSZ electrolyte thickness, (2) cathode interlayer thickness, (3) anode support thickness, and (4) anode support porosity. Cells were tested over a range of temperatures between 600 and 800 °C with hydrogen as fuel, and air as oxidant. Ohmic contribution was determined using the current interruption technique. The effect of these cell parameters on ohmic polarization and on cell performance was experimentally measured. Dependence of cell performance on various parameters was rationalized on the basis of a simple analytical model. Based on the results of the cell parameter study, a cell with optimized parameters was fabricated and tested. The corresponding maximum power density at 800 °C was ∼1.8 W cm⁻².     

Screen-printed thin YSZ films used as electrolytes for solid oxide fuel cells

A thin yttria-stabilized zirconia (8 mol% YSZ) film was successfully fabricated on a NiO-YSZ anode substrate by a screen-printing technique. The scanning electron microscope (SEM) results suggested that the YSZ film thickness was about 31 μm after sintering at 1400 °C for 4 h in air. A 60 wt% La_0.7Sr_0.3MnO₃ + 40 wt% YSZ was screen-printed onto the YSZ film surface as cathode. A single cell was tested from 650 to 850 °C using hydrogen as fuel and ambient air as oxidant, which showed an open circuit voltage (OCV) of 1.02 V and a maximum power density of 1.30 W cm⁻² at 850 °C. The OCV was higher than 1.0 V, which suggested that the YSZ film was quite dense and that the fuel gas leakage through the YSZ film was negligible. Screen-printing can be a promising method for manufacturing YSZ films for solid oxide fuel cells (SOFCs).     

Ni1−xCux alloy-based anodes for low-temperature solid oxide fuel cells with biomass-produced gas as fuel

Ni–Cu alloy-based anodes, Ni_1−xCu_x (x = 0, 0.05, 0.2, 0.3)–Ce_0.8Sm_0.2O_1.9 (SDC), were developed for direct utilization of biomass-produced gas in low-temperature solid oxide fuel cells (LT-SOFCs) with thin film Ce_0.9Gd_0.1O_1.95 electrolytes. The alloys were formed by in situ reduction of Ni_1−xCu_xO_y composites synthesized using a glycine-nitrate technique. The electrolyte films were fabricated with a co-pressing and co-firing technique. Electrochemical performance of the Ni_1−xCu_x–SDC anode supported cells was investigated at 600 °C when humidified (3% H₂O) biomass-produced gas (BPG) was used as the fuel and stationary air as the oxidant. With Ni–Cu alloys as anodes, carbon deposition was substantially suppressed and electrochemical performance of the cells was sustained for much longer periods of time. For example, the power export of a Ni–SDC supported cell was only 50% of the initial value (200 mW cm⁻² at 0.5 V) after 20 min, while Ni_0.8Cu_0.2–SDC supported cells could maintain 90% of the initial power density (250 mW cm⁻² at 0.5 V) over a period of 10 h. The improved performance of the Ni–Cu alloy-based anodes is worth considering in developing SOFCs fueled directly with dilute hydrocarbons such as gases derived from biomass.     

NiO–YSZ cermets supported low temperature solid oxide fuel cells

Solid oxide fuel cells with thin electrolyte of two types, Sm_0.2Ce_0.8O_1.9 (SDC) (15 μm) single-layer and 8 mol% Yttria stabilized zirconia (YSZ) (5 μm) + SDC (15 μm) bi-layer on NiO–YSZ cermet substrates were fabricated by screen printing and co-firing. A Sm_0.5Sr_0.5CoO₃ cathode was printed, and in situ sintered during a cell performance test. The SDC single-layer electrolyte cell showed high electrochemical performance at low temperature, with a 1180 mW cm⁻² peak power density at 650 °C. The YSZ + SDC bi-layer electrolyte cell generated 340 mW cm⁻² peak power density at 650 °C, and showed good performance at 700–800 °C, with an open circuit voltage close to theoretical value. Many high Zr-content micro-islands were found on the SDC electrolyte surface prior to the cathode preparation. The influence of co-firing temperature and thin film preparation methods on the Zr-islands’ appearance was investigated.     

Anode-supported solid oxide fuel cell based on dense electrolyte membrane fabricated by filter-coating

A simple and cost-effective technique, filter-coating, has been developed to fabricate dense electrolyte membranes. Eight mole percent yttria-stabilized zirconia (YSZ) electrolyte membrane as thin as 7 μm was prepared by filter-coating on a porous substrate. The thickness of the YSZ film was uniform, and could be readily controlled by the concentration of the YSZ suspension and the rate of the suspension deposition. The YSZ electrolyte film was dense and was well bonded to the Ni-YSZ anode substrate. An anode-supported solid oxide fuel cell (SOFC) with a YSZ electrolyte film and a La_0.85Sr_0.15MnO₃ (LSM) + YSZ cathode was fabricated and its performance was evaluated between 700 and 850 °C with humidified hydrogen as the fuel and ambient air as the oxidant. An open circuit voltage (OCV) of 1.09 V was observed at 800 °C, which was close to the theoretical value, and the maximum power density measured was 1050 mW cm⁻². The results demonstrate that the dense YSZ film fabricated by filter-coating is suitable for application to SOFCs.     

Ni-SDC cermet anode fabricated from NiO–SDC composite powder for intermediate temperature SOFC

We report a cost-effective processing method for fabricating intermediate temperature solid oxide fuel cells (SOFCs) with Ni-samaria doped ceria (SDC) anode. First, SDC and NiO powders were mechanically treated to make their composite powder. Then, the composite powder was applied into a ceramic tape casting method to form a thick layer for the anode supporting. Finally, an anode supported single cell with a configuration of Ni-SDC/SDC/La_0.6Sr_0.4Co_0.2Fe_0.8O_3 − δ (LSCF) was prepared. Because of the usage of the composite powder, homogenous distribution and connection of each Ni and SDC were achieved. Peak power densities of 460, 750 and 910 mW cm⁻² were obtained on the single cell at 550, 600 and 650 °C, respectively.     

A study of Ni + 8YSZ/8YSZ/La0.6Sr0.4CoO3−δ ITSOFC fabricated by atmospheric plasma spraying

An intermediate temperature solid oxide fuel cell (ITSOFC) based on 8YSZ electrolyte, La_0.6Sr_0.4CoO_3−δ (LSCo) cathode, and Ni − 8YSZ anode coatings were consecutively deposited onto a porous Ni-plate substrate by atmospheric plasma spraying (APS). The spray parameters including current, argon and hydrogen flow rate, and powder feed rate were investigated by an orthogonal experiment to fabricate a thin gas-tight 8YSZ electrolyte coating (80 μm). By proper selection of the spray parameters to decrease the particles velocity and temperature, the sprayed NiO + 8YSZ coating after reducing with hydrogen shows a good electrocatalytic activity for H₂ oxidation. With the same treatment, 100–170 μm dimensions LSCo particle could keep phase structure after spraying. And the deposited LSCo cathode shows a good cathode performance and chemical compatibility with 8YSZ electrolyte after operating at 800 °C for 50 h. Output power density of the sprayed cell achieved 410 mW cm⁻² at 850 °C and 260 mW cm⁻² at 800 °C. Electrochemical characterization indicated that IR drop of 8YSZ electrolyte, cathodic polarization, and the contact resistance at LSCo/8YSZ interface were the main factors restricting the cell performance. The results suggested that the use of APS cell allowed the reduction of the operating temperature of the SOFC to below 850 °C with lower production costs.     

The effect of a ceria coating on the H2S tolerance of a molten carbonate fuel cell

To enhance the performance of anodes in molten carbonate fuel cells (MCFCs), in terms of their sulfur tolerance, we modified the surface characteristics of a conventional Ni–10 wt% Cr anode through dip coating using a ceria sol. The performance of the ceria-coated anode was 0.4 V higher than that of the uncoated anode when H₂S (80 ppm) was introduced under a current density of 150 mA cm⁻² for 180 h. H₂S acted as a poison of the non-modified Ni electrode, regardless of its operating conditions, to form Ni₃S₂, which caused the voltage drop. The ceria-coated anode had the ability to suppress such a voltage drop because ceria can react with H₂S to form Ce₂O₂S. Our results suggest that the presence of a CeO₂ coating layer can reduce the degree of sulfur poisoning of the anode under the operating conditions – e.g., a reducing atmosphere and a high temperature – experienced by MCFCs.     

Analysis of the regenerative H2S poisoning mechanism in Ce0.8Sm0.2O2-coated Ni/YSZ anodes for intermediate temperature solid oxide fuel cells

Ceria is used as a sulfur sorbent due to its high affinity for sulfide at high temperatures. In addition, the ionic conductivity of ceria can be dramatically increased by doping with rare metals, including lanthanum, samarium, and gadolinium. Therefore, to enhance sulfur tolerance and improve anode performance, we modified an Ni-based anode with a thin layer coating of Sm_0.2Ce_0.8O_2−δ (SDC) on the pore wall surface of an Ni/YSZ anode. The anode-supported cells were tested with varying H₂S concentrations (0-100 ppm) at 600 and 700 °C. The cell performance was improved in the ceria- (by 20%) and in the SDC- (by 50%) modified anode by extending the additional TPB area in the anode. Under varying H₂S exposure, the polarization resistance was reduced by ceria and the SDC coating on the anode pore wall surface, which led to improved cell performance. A porous SDC layer on the Ni/YSZ anode pore wall acted as a sulfur sorbent as well as an additional TPB area. Otherwise, ceria mainly acted as a sulfur sorbent at high concentrations of H₂S (>60 ppm).     

Performance of direct methanol fuel cell using carbon nanotube-supported Pt–Ru anode catalyst with controlled composition

The performance of a single-cell direct methanol fuel cell (DMFC) using carbon nanotube-supported Pt–Ru (Pt–Ru/CNT) as an anode catalyst has been investigated. In this study, the Pt–Ru/CNT electrocatalyst was successfully synthesized using a modified polyol approach with a controlled composition very close to 20 wt.%Pt–10 wt.%Ru, and the anode was prepared by coating Pt–Ru/CNT electrocatalyst on a wet-proof carbon cloth substrate with a metal loading of about 4 mg cm⁻². A commercial gas diffusion electrode (GDE) with a platinum black loading of 4 mg cm⁻² obtained from E-TEK was employed as the cathode. The membrane electrode assembly (MEA) was fabricated using Nafion^® 117 membrane and the single-cell DMFC was assembled with graphite endplates as current collectors. Experiments were carried out at moderate low temperatures using 1 M CH₃OH aqueous solution and pure oxygen as reactants. Excellent cell performance was observed. The tested cell significantly outperformed a comparison cell using a commercial anode coated with carbon-supported Pt–Ru (Pt–Ru/C) electrocatalyst of similar composition and loading. High conductivity of carbon nanotube, good catalyst morphology and suitable catalyst composition of the prepared Pt–Ru/CNT electrocatalyst are considered to be some of the key factors leading to enhanced cell performance.     

High power-density single-chamber fuel cells operated on methane

Single-chamber solid oxide fuel cells (SC-SOFCs) incorporating thin-film Sm_0.15Ce_0.85O_1.925 (SDC) as the electrolyte, thick Ni + SDC as the (supporting) anode and SDC + BSCF (Ba_0.5Sr_0.5Co_0.8Fe_0.2O_3−δ) as the cathode were operated in a mixture of methane, oxygen and helium at furnace temperatures of 500–650 °C. Because of the exothermic nature of the oxidation reactions that occur at the anode, the cell temperature was as much as 150 °C greater than the furnace temperature. Overall, the open circuit voltage was only slightly sensitive to temperature and gas composition, varying from ∼0.70 to ∼0.78 V over the range of conditions explored. In contrast, the power density strongly increased with temperature and broadly peaked at a methane to oxygen ratio of ∼1:1. At a furnace temperature of 650 °C (cell temperature ∼790 °C), a peak power density of 760 mW cm⁻² was attained using a mixed gas with methane, oxygen and helium flow rates of 87, 80 and 320 mL min⁻¹ [STP], respectively. This level of power output is the highest reported in the literature for single chamber fuel cells and reflects the exceptionally high activity of the BSCF cathode for oxygen electro-reduction and its low activity for methane oxidation.     

Yttria-stabilized zirconia thin films deposited on NiO–(Sm2O3)0.1(CeO2)0.8 substrates by chemical vapor infiltration

Fabrication of YSZ films deposited on NiO–samaria-doped ceria (SDC) substrate was studied by the chemical vapor infiltration method (CVI). A NiO–SDC substrate was used as oxygen source. The main mechanism of YSZ growth was electrochemical vapor deposition (EVD), while the contribution of oxygen in the carrier gas increased with increasing NiO content of the substrate above 60.6 mol%. The YSZ film on SDC used as the anode proved effective in obtaining high cell performance. In particular, a YSZ film thickness of 1 μm yielded the highest cell performance in the temperature range from 973 to 1073 K. The CVI method was useful for preparing a dense and strong YSZ film on the complex-shaped NiO–SDC substrate.     

Operation of PEM fuel cells at 120–150 °C to improve CO tolerance

Sulfonic acid modified perfluorocarbon polymer proton exchange membrane (PEM) fuel cells operated at elevated temperatures (120–150 °C) can greatly alleviate CO poisoning on anode catalysts. However, fuel cells with these PEMs operated at elevated temperature and atmospheric pressure typically experience low relative humidity (RH) and thus have increased membrane and electrode resistance. To operate PEM fuel cells at elevated temperature and high RH, work is needed to pressurize the anode and cathode reactant gases, thereby decreasing the efficiency of the PEM fuel cell system. A liquid-fed hydrocarbon-fuel processor can produce reformed gas at high pressure and high relative humidity without gas compression. If the anode is fed with this high-pressure, high-relative humidity stream, the water in the anode compartment will transport through the membrane and into the ambient pressure cathode structure, decreasing the cell resistance. This work studied the effect of anode pressurization on the cell resistance and performance using an ambient pressure cathode. The results show that high RH from anode pressurization at both 120 and 150 °C can decrease the membrane resistance and therefore increase the cell voltage. A cell running at 150 °C obtains a cell voltage of 0.43 V at 400 mA cm⁻² even with 1% CO in H₂. The results presented here provide a concept for the application of a coupled steam reformer and PEM fuel cell system that can operate at 150 °C with reformate and an atmospheric air cathode.     

Modifying the cathodes of intermediate-temperature solid oxide fuel cells with a Ce0.8Sm0.2O2 sol–gel coating

To increase the performance of solid oxide fuel cells operated at intermediate temperatures (<700 °C), we used the electronic conductor La_0.8Sr_0.2MnO₃ (LSM) and the mixed conductor La_0.6Sr_0.4Co_0.2Fe_0.8O₃ (LSCF) to modify the cathode in the electrode microstructure. For both cathode materials, we employed a Sm_0.2Ce_0.8O₂ (SDC) buffer layer as a diffusion barrier on the yttria-stabilized zirconia (YSZ) electrolyte to prevent the interlayer formation of SrZrO₃ and La₂Zr₂O₇, which have a poor ionic conductivity. These interfacial reaction products were formed only minimally at the electrolyte–cathode interlayer after sintering the SDC layer at high temperature; in addition, the degree of cathode polarization also decreased. Moreover to extend the triple phase boundary and improve cell performance at intermediate temperatures, we used sol–gel methods to coat an SDC layer on the cathode pore walls. The cathode resistance of the LSCF cathode cell featuring SDC modification reached as low as 0.11 Ω cm² in air when measured at 700 °C. The maximum power densities of the cells featuring the modified LSCF and LSM cathodes were 369 and 271 mW/cm², respectively, when using O₂ as the oxidant and H₂ as the fuel.