A strategy of tailoring stable electrolyte material for high performance proton-conducting solid oxide fuel cells (SOFCs)

A facile strategy was proposed to synthesize Nb-containing BaCeO₃-based material, which is a potential electrolyte for proton-conducting solid oxide fuel cells (SOFCs), via a wet chemical route while the conventional synthesis of Nb-containing oxides relied on the solid state reaction method due to the unavailability of suitable Nb-precursors such as Nb-nitrates resulting in a less desirable fuel cell performance when used as an electrolyte. The BaCe_0.7Nb_0.1Y_0.2O_3 − δ (BCNY) electrolyte material in this study persisted a good chemical stability against CO₂ and exhibited good performance in the fuel cell application. The fuel cell with BCNY electrolyte film showed a high performance of 533 mW cm^− 2 at 700 °C. This cell performance based on BCNY electrolyte was superior to that of many stable modified BaCeO₃-based proton-conducting SOFCs where the electrolytes were tailored by other strategies. This result indicated that the strategy presented in this study could be an effective way to prepare a stable electrolyte for high performance proton-conducting SOFCs, which could advance the development of proton-conducting SOFCs.     

Effects of CuO addition to anode on the electrochemical performances of cathode-supported solid oxide fuel cells

A cathode-supported electrolyte film was fabricated by tape casting and co-sintering techniques. (La_0.8Sr_0.2)_0.95MnO₃ (LSM95), LSM95/Zr_0.89Sc_0.1Ce_0.01O_2?x (SSZ), and SSZ were used as materials of cathode substrate, cathode active layer, and electrolyte, respectively. CuO–NiO–SSZ composite anode was deposited on SSZ surface by screen-printing and sintered at 1250 °C for 2 h. The effects of CuO addition to NiO–SSZ anode on the performance of cathode-supported SOFCs were investigated. CuO can effectively improve the sintering activity of NiO–SSZ. The assembled cells were electrochemically characterized with humidified H₂ as fuel and O₂ as oxidant. With 4 wt.% CuO addition, the ohmic resistance decreased from 3 to 0.46 Ω cm², and at the same time the polarization resistance decreased from 3.4 to 0.74 Ω cm². In comparison with the cell without CuO, the maximum power density at 850 °C increased from 0.054 to 0.446 W cm^?2 with 4 wt.% CuO addition.     

Chemically stable anode-supported solid oxide fuel cells based on Y-doped barium zirconate thin films having improved performance

Anode-supported solid oxide fuel cells (SOFCs) based on thin BaZr_0.8Y_0.2O_3 ? δ (BZY) electrolyte films were fabricated by pulsed laser deposition (PLD) on sintered NiO–BZY composite anodes. After in situ reduction of NiO to Ni, the anode substrates became porous, while retaining good adhesion with the electrolyte. A slurry-coated composite cathode made of La_0.6Sr_0.4Co_0.2Fe_0.8O_3 ? δ (LSCF) and BaCe_0.9Yb_0.1O_3 ? δ (BCYb), specifically developed for proton conducting electrolytes, was used to assemble fuel cell prototypes. Depositing by PLD 100 nm thick LSCF porous films onto the BZY thin films was essential to improve the cathode/electrolyte adhesion. A power density output of 110 mW/cm² at 600 °C, the largest reported value for an anode-supported fuel cell based on BZY at this temperature, was achieved. Electrochemical impedance spectroscopy (EIS) measurements were used to investigate the different contributions to the total polarization losses.     

Temperature-dependent Raman spectroscopy studies of phase transformations in the K2WO4 and the MgMoO4 crystals

Temperature-dependent Raman spectroscopy studies of K₂WO₄ and MgMoO₄ polycrystals were performed in order to obtain information about vibrational and structural changes in these materials as a function of temperature. The stability of the monoclinic phase for both K₂WO₄ and MgMoO₄ samples was assessed and our results indicated that this phase is stable in the 295–723 K and 300–770 K ranges for K₂WO₄ and MgMoO₄, respectively. It was observed that both samples underwent two phase transformations above room temperature. The first phase transformations which occur at about 633 K and 640 K for K₂WO₄ and MgMoO₄, respectively, is most likely connected with weak tilting and/or rotations of WO₄/MoO₄ tetrahedral units that lead to a disorder in the oxygen sublattice. Raman spectroscopy data also indicated that K₂WO₄ and MgMoO₄ exhibited a first-order phase transition at around 723 K and 770 K, respectively, changing from monoclinic to hexagonal symmetry.     

Fabrication of needle-type micro SOFCs for micro power devices

We report the world smallest tubular solid oxide fuel cell – needle-type micro SOFCs applicable to micro power devices. The anode-supported cell was prepared using cost effective, conventional extrusion and dip-coating techniques. The diameter of the needle-type cell is 0.4 mm, consisting of NiO-Gd doped Ceria (GDC) for anode (under 100 μm thick), GDC for electrolyte (8 μm thick), and (La, Sr) (Co, Fe)O₃ – GDC for cathode. The cell performances of 80, 160 and 300 mW cm⁻² at 450 °C, 500 °C, and 550 °C, respectively, were obtained using a simple current collection method with wet H₂ fuel. Impedance analysis indicated that the SOFC has a potential to be improved by optimizing the current collection method. Bundle concept using the SOFCs with the packing density of 100 cells in 1 cm³ was also proposed.     

Development of novel low-temperature SOFCs with co-ionic conducting SDC-carbonate composite electrolytes

A series of ceria-based composite materials consisting of samaria doped ceria (SDC) and binary carbonates(Li₂CO₃–Na₂CO₃) were examined as functional electrolytes for low-temperature solid oxide fuel cells (SOFCs). DTA and SEM techniques were applied to characterize the phase- and micro-structural properties of the composite materials. Conductivity measurements were carried on the composite electrolytes with a.c. impedance in air. A transition of ionic conductivity with temperature was occurred among all samples with different carbonate content, which related to the interface phase. Single cells based on the composite electrolytes, NiO as anode and lithiated NiO as cathode, were fabricated by a simple dry-pressing process and tested at 400–600 °C. The maximum output power at 600 °C increased with the carbonate content in the composite electrolytes, and reached the maximum at 25 wt.%, then decreased. Similar trend has also shown at 500 °C, but the maximum was obtained at 20wt.%. The best performances of 1085 mW cm⁻² at 600 °C and 690 mW cm⁻² at 500 °C were achieved for the composite electrolytes containing 25 and 20 wt.% carbonates, respectively. During fuel cell operation, it found that the SDC-carbonate composites are co-ionic (O²⁻/H⁺) conductors. At lower carbonate contents, both oxide–ion and proton conductions were significant, when the content increased to 20–35 wt.%, proton conduction dominated. The detailed conduction mechanism in these composites needs further investigation.     

Proton-conducting solid oxide fuel cell (SOFC) with Y-doped BaZrO3 electrolyte

Y-doped BaZrO₃ (BZY) electrolyte films are successfully fabricated by utilizing the driving force from the anode substrate, aiming to circumvent the refractory nature of BZY materials. The BZY electrolyte film on the high shrinkage anode becomes dense after sintering even though no sintering aid is added, while the BZY electrolyte remains porous on the conventional anode substrate after the same treatment. The resulting BZY electrolyte shows a high conductivity of 4.5 × 10^− 3 S cm^− 1 at 600 °C, which is 2 to 20 times higher than that for most of BZY electrolyte films in previous reports. In addition, the fuel cell with this BZY electrolyte generates a high power output of 267 mW cm^− 2 at 600 °C. These results suggest the strategy presented in this study provides a promising way to prepare BZY electrolyte films for fuel cell applications.     

A novel single phase cathode material for a proton-conducting SOFC

A novel single phase BaCe_0.5Bi_0.5O_3 ? δ (BCB) was employed as a cathode material for a proton-conducting solid oxide fuel cell (SOFC). The single cell, consisting of a BaZr_0.1Ce_0.7Y_0.2O_3 ? δ (BZCY7)-NiO anode substrate, a BZCY7 anode functional layer, a BZCY7 electrolyte membrane and a BCB cathode layer, was assembled and tested from 600 to 700 °C with humidified hydrogen (～3% H₂O) as the fuel and the static air as the oxidant. An open-circuit potential of 0.96 V and a maximum power density of 321 mW cm^?2 were obtained for the single cell. A relatively low interfacial polarization resistance of 0.28Ω cm² at 700 °C indicated that the BCB was a promising cathode material for proton-conducting SOFCs.     

Anisotropic catalytic activity of the orientation controlled Nd2NiO4 + δ/YSZ hetero-epitaxial system for SOFC cathode

Electrode–electrolyte hetero-epitaxial systems for solid oxide fuel cells (SOFCs) with two different configuration of Nd₂NiO_4 + δ(110)//YSZ(100) and Nd₂NiO_4 + δ(100)//YSZ(110) were successfully fabricated by pulsed laser deposition. Thin films of Nd₂NiO_4 + δ approximately 20 nm thick were grown on a commercial single crystal of YSZ. The preferred two-dimensional diffusion paths of the oxide ions were perpendicular to the substrate for both configurations and showed oxygen reduction capability different from each other. This opens up new research direction focusing on the details of anisotropic catalytic activity of SOFC cathode depending on the crystalline surface.     

A cobalt-free electrode material La0.5Sr0.5Fe0.8Cu0.2O3 − δ for symmetrical solid oxide fuel cells

Cobalt-free perovskite oxide La_0.5Sr_0.5Fe_0.8Cu_0.2O_3 − δ (LSFC) was applied as both anode and cathode for symmetrical solid oxide fuel cells (SSOFCs). The LSFC shows a reversible transition between a cubic perovskite phase in air and a mixture of SrFeLaO₄, a K₂NiF₄-type layered perovskite oxide, metallic Cu and LaFeO₃ in reducing atmosphere at elevated temperature. The average thermal expansion coefficient of LSFC in air is 17.7 × 10^− 6 K^− 1 at 25 °C to 900 °C. By adopting LSFC as initial electrodes to fabricate electrolyte supported SSOFCs, the cells generate maximum power output of 1054, 795 and 577 mW cm^− 2 with humidified H₂ fuel (~ 3% H₂O) and 895, 721 and 482 mW cm^− 2 with humidified syngas fuel (H₂:CO = 1:1) at 900, 850 and 800 °C, respectively. Moreover, the cell with humidified H₂ fuel demonstrates a reasonable stability at 800 °C under 0.7 V for 100 h.     

Enhanced performance of an anode-supported YSZ thin electrolyte fuel cell with a laser-deposited Sm0.2Ce0.8O1.9 interlayer

A power density of over 1.4 W cm^?2 at 0.7 V was achieved at 750 °C for an anode-supported YSZ thin electrolyte fuel cell with a dense Sm_0.2Ce_0.8O_1.9 (SDC) interlayer fabricated by pulsed laser deposition, while the cell with a conventional porous SDC interlayer exhibited only 0.8 W cm^?2 at this voltage. The dense SDC interlayer significantly reduced the ohmic resistance of the fuel cell. For example, at 750 °C, the ohmic resistance of the fuel cell with a dense SDC interlayer was 0.08 Ω cm²; while that of the cell with a porous SDC interlayer fabricated by conventional screen-printing was 0.16 Ω cm². The pronounced reduction in ohmic resistance might be due to the fully dense structure and thus improved electrical conductivity of the SDC interlayer, increased contact area at the interface between the dense SDC interlayer and the YSZ electrolyte, and suppressed Zr migration into the SDC interlayer.     

A novel polymeric electrolyte based on a copolymer containing self-assembled stearylate moiety for lithium-ion batteries

A novel polymeric electrolyte based on a self-assembled copolymer moiety has been prepared by a simple method of photo-induced radical polymerization of a mixture consisting of stearylmethacrylate (SMA) and poly(ethylene glycol)-monomethacrylate (PEM) that dissolves LiBF₄ as the electrolytic salt. The SMA moiety work as mechanically stable backbone and the PEM unit dissolving the salts serves as ion-conducting path in the polymeric composite. Solid-state NMR measurements indicated that the resulting polymer composite consists of PEM-rich and SMA-rich phases, each of which exists within several nanometers apart. The ionic conductivity of the polymer electrolyte with the composition of PEM/SMA = 7/3 (by mass ratio) was 2.8 × 10^?5 S cm^?1 at 50 °C, which was significantly higher than that of the polymer electrolyte based on cross-linked PEM copolymer without SMA.     

Novel core–shell SDC/amorphous Na2CO3 nanocomposite electrolyte for low-temperature SOFCs

Novel core–shell SDC (Ce_0.8Sm_0.2O_1.9)/amorphous Na₂CO₃ nanocomposite was prepared for the first time. The core–shell nanocomposite particles are smaller than 100 nm with amorphous Na₂CO₃ shell of 4–6 nm in thickness. The nanocomposite electrolyte shows superionic conductivity above 300 °C, where the conductivity reaches over 0.1 S cm⁻¹. Such high conductive nanocomposite has been applied in low-temperature solid oxide fuel cells (LTSOFCs) with an excellent performance of 0.8 W cm⁻² at 550 °C. A new potential approach of designing and developing superionic conductors for LTSOFCs was presented to develop interface as ‘superionic highway’ in two-phase materials based on coated SDC.     

Composite cathode for IT-SOFC: Sr-doped lanthanum cuprate and Gd-doped ceria

Composite cathodes were synthesized via a citrate combustion method followed by an organic precipitation method. The cathodes were of K₂NiF₄-type crystal structure with x wt.% Ce_0.9Gd_0.1O_1.95 (CGO)–(100 ? x) wt.% La_1.96Sr_0.04CuO_4 + δ (LSC), where x = 0, 10, 20 and 30. The individual structural phases of the composite cathodes were characterized using a third-generation synchrotron source beamline powder X-ray diffractometer (XRD). The porous grain morphology of the CGO–LSC cathode composite for a symmetrical half-cell was determined from cross-sectional scanning electron microscopy images and elemental line profiles. The composite cathode was made of 20 wt.% CGO–80 wt.% LSC (CL20–80) and was coated onto a Ce_0.9Gd_0.1O_1.95 electrolyte. It showed the lowest area specific resistance (ASR) of 0.07 Ω cm² at 750 °C. An electrolyte-supported (300 μm thick) single-cell configuration of CL20–80/CGO/Ni-CGO attained a maximum power density of 626 mW cm^? 2 at 700 °C. The unique composite composition of CL20–80 demonstrates enhanced electrochemical performance and good chemical compatibility with the CGO electrolyte, as compared with the pure LSC (CL0–100) cathode for IT-SOFCs.     

High performance cathode-supported SOFC with perovskite anode operating in weakly humidified hydrogen and methane

A high performance cathode-supported solid oxide fuel cell (SOFC), suitable for operating in weakly humidified hydrogen and methane, has been developed. The SOFC is essentially made up by a YSZ/LSM composite supporting cathode, a thin YSZ film electrolyte, and a GDC-impregnated La_0.75Sr_0.25Cr_0.5Mn_0.5O₃ (LSCM) anode. A gas tight thin YSZ film (∼27 μm) was formed during the co-sintering of cathode/electrolyte bi-layer at 1200 °C. The cathode-supported SOFC developed in this study showed encouraging performance with maximum power density of 0.182, 0.419, 0.628 and 0.818 W cm⁻² in air/3% H₂O–97% H₂ (and 0.06, 0.158, 0.221 and 0.352 W cm⁻² in air/3% H₂O–97% CH₄) at 750, 800, 850 and 900 °C, respectively. Such performance is close to that of the cathode-supported cell (0.42 W cm⁻² vs. 0.455 W cm⁻² in humidified H₂ at 800 °C) developed by Yamahara et al. [Solid State Ionics 176 (2005) 451–456] with a Co-infiltrated supporting LSM-YSZ cathode, a (Sc₂O₃)_0.1(Y₂O₃)_0.01(ZrO₂)_0.89 (SYSZ) electrolyte of 15 μm in thickness and a SYSZ/Ni anode, indicating that the performance of the GDC-impregnated LSCM anode is comparable to that made of Ni cermet while stable in weakly humidified methane fuel.     

Electrochemical performances of LaBaCuFeO5+x and LaBaCuCoO5+x as potential cathode materials for intermediate-temperature solid oxide fuel cells

Layered perovskite-structure oxides LaBaCuFeO_5+x (LBCFO) and LaBaCuCoO_5+x (LBCCO) were prepared and the electrical conductivity and electrochemical performance were investigated as potential cathode materials for intermediate-temperature solid oxide fuel cells (IT-SOFCs). The electrical conductivity of LBCCO is much higher than that of LBCFO. Area specific resistances of LBCFO and LBCCO cathode materials on Ce_0.8Sm_0.2O_1.9 (SDC) electrolyte are as low as 0.21 Ω cm² and 0.11 Ω cm² at 700 °C, respectively. The maximum power density of the LBCFO/SDC/Ni-SDC and LBCCO/SDC/Ni-SDC cells with 300 μm thick electrolytes attains 557 mW cm^?2 and 603 mW cm^?2 at 800 ^oC, respectively. Preliminary results demonstrated that the layered perovskite-structure oxides LBCFO and LBCCO are very promising cathode materials for application in IT-SOFCs.     

Quantitative three-dimensional microstructure of a solid oxide fuel cell cathode

Solid oxide fuel cells (SOFCs) are being actively developed world wide for clean and efficient electrical generation from fuels such as natural gas, hydrogen, coal, and gasoline. The cathode in state of the art SOFCs is typically a porous composite of electronically-conducting La_1?xSr_xMnO₃ (LSM) and ionically-conducting Y₂O₃-stabilized ZrO₂ (YSZ) that facilitates the critical oxygen reduction reaction. Here we describe the three-dimensional characterization and quantification of key structural parameters from an LSM-YSZ cathode, using imaging and volume reconstruction based on focused ion beam – scanning electron microscopy. LSM-YSZ-pore three-phase boundaries (TPBs) were identified. Approximately 1/3 of the TPBs were found to be electrochemically inactive, as they were on isolated LSM particles, yielding an active TPB density of 4.9 μm^?2. Cathode electrochemical modeling, which included a measured YSZ tortuosity of 3.4, yielded an effective TPB resistance of ≈2.5 × 10⁵ Ω cm at 800 °C.     

Li2SO4-polyacrylamide polymer electrolytes for 2.0 V solid symmetric supercapacitors

A neutral polymer electrolyte comprised of lithium sulfate (Li₂SO₄) and polyacrylamide (PAM) was developed. The Li₂SO₄-PAM electrolyte film shows an ionic conductivity up to 10 mS cm^− 1 in 45%RH conditions. Solid double layer capacitors were demonstrated using CNT-graphite electrodes and Li₂SO₄-PAM solid electrolytes. The voltage window of the solid cell was about 2.0 V, identical to that of a Li₂SO₄ liquid cell used as baseline. The demonstrated voltage window is significantly larger than that reported for proton- or hydroxyl-conducting electrolytes, suggesting that the Li₂SO₄-PAM electrolyte is a promising system for high energy density supercapacitors. The solid device also demonstrated excellent rate capability (up to 5 V s^− 1) and good cycle life (beyond 10,000 charge/discharge cycles).     

Cobalt-free cathode material SrFe0.9Nb0.1O3−δ for intermediate-temperature solid oxide fuel cells

A cobalt-free cubic perovskite oxide, SrFe_0.9Nb_0.1O_3?δ (SFN) was investigated as a cathode for intermediate-temperature solid oxide fuel cells (IT-SOFCs). XRD results showed that SFN cathode was chemically compatible with the electrolyte Sm_0.2Ce_0.8O_1.9 (SDC) for temperatures up to 1050 °C. The electrical conductivity of SFN sample reached 34–70 S cm^?1 in the commonly operated temperatures of IT-SOFCs (600–800 °C). The area specific resistance was 0.138 Ω cm² for SFN cathode on SDC electrolyte at 750 °C. A maximum power density of 407 mW cm^?2 was obtained at 800 °C for single-cell with 300 μm thick SDC electrolyte and SFN cathode.     

High-performance bilayered electrolyte intermediate temperature solid oxide fuel cells

The ESB/GDC bilayer electrolyte concept has been proved to improve open circuit voltage and reduce the effective area specific resistance of SOFCs utilizing a conventional single-layer GDC electrolyte. However, high performance from such bilayer cells had not yet been demonstrated. The main obstacles toward this end have been fabrication of anode-supported thin-film electrolytes and the reactivity of ESB with conventional cathodes. Recently, an ESB-compatible low area specific resistance cathode was developed: microstructurally optimized Bi₂Ru₂O₇-ESB composites. In addition, we recently developed a novel anode functional layer which can significantly enhance the performance of SOFC utilizing GDC electrolytes. This study combines these recent achievements in SOFC studies and shows that exceptionally high performance of SOFC is possible using ESB/GDC bilayer electrolytes and Bi₂Ru₂O₇-ESB composite cathodes. The result confirms that the bilayer electrolyte and the Bi₂Ru₂O₇-ESB cathode can increase the open circuit potential and reduce the total area specific resistance. The maximum power density of the bilayered SOFC was improved to 1.95 W cm^?2 with 0.079 Ω cm² total cell area specific resistance at 650 °C. This is the highest power yet achieved in the IT range and we believe redefines the expectation level for maximum power under IT-SOFC operating conditions.