Characterization of NiO–yttria stabilised zirconia (YSZ) hollow fibres for use as SOFC anodes

NiO–yttria stabilised zirconia (YSZ) hollow fibres with varying NiO content and a desired microstructure were prepared using a phase inversion technique and sintering. By controlling the fabrication parameters, microstructures with predominately finger-like pores near the inner and outer surfaces and a denser central layer with sponge-like pores were produced, for use as substrates for anode-supported hollow fibre solid oxide fuel cells (HF-SOFC). The NiO–YSZ fibres were reduced to Ni–YSZ at 250–700 °C in hydrogen flowing at 20 cm³ min^? 1 to produce Ni–YSZ hollow fibres, the mechanical and electrical properties of which were determined subsequently, reduction to Ni being verified by X-ray diffraction. The effects of NiO concentration and sintering temperature of the fibre precursors on the conductivity, strength and porosity of the reduced hollow fibres were investigated to assess their suitability for use as anode substrates. As expected, increasing Ni concentration increased electrical conductivities and decreased mechanical strength. Sintering temperature had a critical effect in producing axially conductive hollow fibres of sufficient mechanical strength for use as SOFC anodes. The hollow fibres retained their initial microstructure through the reduction process, though ca. 41% volume contraction is predicted on reduction of NiO to Ni, producing increased porosity in the reduced fibres. The mean porosity of the Ni–YSZ hollow fibres was ca. 60% and ca. 40% after sintered at 1250 °C and 1400 °C, respectively. The mean pore sizes for all the fibres after reduction varied between ca. 0.3 and 1 µm. The hollow fibres produced with 60% NiO, of length ca. 300 mm, electrical conductivities of ca. (1–2.25) × 10⁵ S m^? 1 and a porosity of ca. 43% are being used currently to construct and test the electrical behaviour of an anode-supported HF-SOFC.     

The influence of pore and Ni morphology on the electrical conductivity of porous Ni/YSZ composite anodes for use in solid oxide fuel cell applications

A wide range of porous Ni–YSZ composite microstructures was produced by conventional tape casting and co-sintering using a variety of starting powders including Ni, NiO, graphite and Ni-coated graphite. The graphite additions were added to produce controlled levels of porosity in the final sintered and reduced anode. All materials indicated classical conductivity percolation behaviour with increasing Ni loadings. However, the percolation threshold at which electrical conduction became measurable was lowest for anodes made with Ni-coated graphite and highest for anodes containing large amounts of porosity introduced by large additions of graphite. Sintered and reduced anodes possessed large scale porosity introduced by the graphite additions and a finer scale porosity generated by the incomplete sintering of the Ni/YSZ powder network. A model was developed for predicting the influence of large scale porosity on conductivity and agreed well with the experimental results. The analysis indicates that fine scale porosity will have a more detrimental impact on conductivity compared to a coarse porous structure.     

Electrical conductivity of thick film YSZ

When yttria-stabilized zirconia (YSZ) electrolyte is coated and co-sintered on top of Ni–YSZ anode support, the measured conductivities of YSZ thick films (10–30 μm thick) are often lower than that of bulk YSZ. In this study, we found the observation by fabricating free-standing YSZ thick films and measuring and comparing in-plain and across-plain conductivities. The in-plane conductivity of free-standing YSZ film matched very well with the conductivity of mm-thick bulk sample. It was further shown that the conductivity decrease can be minimized by using better electrode morphology.Another factor that decreases the film conductivity was identified when the thick film was reduced. The conductivity decrease, ∼26% after reduction for 1h in humidified hydrogen gas, was due to Ni-doping into YSZ during sintering process.In order to minimize the conductivity drop of thick film YSZ during SOFC (solid oxide fuel cell) operation, an intermediate layer may be used between YSZ and anode support to prevent Ni-doping during co-sintering process in addition to the well-designed electrode morphology.     

Processing and characterization of ultra-thin yttria-stabilized zirconia (YSZ) electrolytic films for SOFC

Sub-micron yttria-stabilized zirconia (YSZ) electrolyte layer was prepared by a liquid state deposition method and with an average thickness of 0.5 μm to improve the performance of the anode-supported solid oxide fuel cell (SOFC). The YSZ precursors, containing yttrium and zirconium species and an additive, poly-vinyl-pyrrolidone (PVP), were spin-coated on a Ni/YSZ anode substrate. Several properties, including crystalline phases, microstructures, and current–voltage (I–V) characteristics, were investigated. The thin film of 4 mol% Y₂O₃-doped ZrO₂ (4YSZ) consisted of cubic, tetragonal, and a trace of monoclinic phases, and showed a crack-free layer after sintering at 1300 °C. The anode supported SOFC, which consists of the Ni–YSZ anode, 4YSZ electrolyte, and Pt/Pd cathode, showed power densities of 477 mW/cm² at 600 °C, and 684 mW/cm² at 800 °C. Otherwise, the surface cracks of the other YSZ-coated samples (e.g. 8YSZ) can be repaired by a multi-coating method.     

CeO<Subscript>2</Subscript> and Nb<Subscript>2</Subscript>O<Subscript>5</Subscript> modified Ni-YSZ anode for solid oxide fuel cell

Ni sintering at high temperature (～ 800 °C) operation drastically degrades the performance of Ni-yttria-stabilized zirconia (YSZ) anode in solid oxide fuel cell (SOFC). Mixed ionic and electronic conductive oxides such as CeO₂ and Nb₂O₅ enhance the dispersion of Ni, CeO₂ enhances the redox behavior and promotes charge transfer reactions, and Nb₂O₅ increases the triple phase boundary. In the present work, anode-supported SOFC is fabricated and tested in H₂ fuel at 800 °C. YSZ and lanthanum strontium manganite (LSM)-YSZ are used as the electrolyte and composite cathode with NiO-YSZ, CeO₂-NiO-YSZ, and Nb₂O₅-NiO-YSZ as an anode. The peak power density obtained for the cell with 10% CeO₂–30% NiO-YSZ anode at the 5 and 25 h of operation is 330 and 290 mW cm^?2 which is higher than that for 40% NiO-YSZ anode (275 mW cm^?2 at 5 h). The peak power density obtained for the cell with 10% Nb₂O₅–30% NiO-YSZ anode at the 5 and 25 h of operation is 301 and 285 mW cm^?2 which is higher than that for 40% NiO-YSZ anode (275 mW cm^?2 at 5 h). Physical characterization has been carried to study morphology, elemental analysis, particle size, and phase formation of the fabricated anode before and after cell operation to correlate the cell performance.     

Electrical conductivity of yttria-stabilized zirconia with cobalt addition

Yttria-stabilized zirconia is the most developed solid electrolyte for use in high-temperature solid oxide fuel cells. Commercial yttria-stabilized zirconia powders reach high densification at temperatures higher than that of the usual anode materials. Reduction of the sintering temperature of the solid electrolyte could allow for co-firing of both ceramic components, thereby reducing production costs. The main purpose of this work was to study the effect of small cobalt additions on densification and on electrical conductivity of 8 mol% yttria-stabilized zirconia. Linear shrinkage results show that the onset temperature for shrinkage decreases with increasing cobalt content. Impedance spectroscopy measurements reveal that the electrical conductivity depends on the sintering profile. For specimens sintered at 1400 °C for 0.1 h the electrical conductivity of grains and grain boundaries are almost unchanged with that of 8YSZ. In contrast, for specimens sintered at the same temperature but for 0.5 h of soaking time, the electrical conductivity is higher in 0.025 mol% samples and is lower for 1 mol% Co doped 8YSZ. Degradation of the microstructure by increased porosity was obtained for high additive contents.     

Microstructure and performance of novel Ni anode for hollow fibre solid oxide fuel cells

Nickel anodes were deposited on hollow fibre yttria-stabilised zirconia (YSZ) electrolyte substrates for use in solid oxide fuel cells (SOFCs). The hollow fibres are characterised by porous external and internal surfaces supported by a central gas-tight layer (300 μm total wall thickness and 1.6 mm external diameter). The YSZ hollow fibres were prepared by a phase inversion technique followed by high temperature sintering in the range 1200 to 1400 °C. Ni anodes were deposited on the internal surface by electroless plating involving an initial catalyst deposition step with PdCl₂ followed by Ni plating (with a NiSO₄, NaH₂PO₂ and sodium succinate based solution at 70 °C). Fabrication and nickel deposition parameters (nature of solvents, air gap, temperature, electroless bath composition) and heat treatments in oxidising/reducing environments were investigated in order to improve anode and electrolyte microstructure and fuel cell performance. A parallel study of the effect of YSZ sintering temperature, which influences electrolyte porosity, on electrolyte/anode microstructure was performed on mainly dense discs (2.3 mm thick and 15 mm diameter). Complete cells were tested with both disc and hollow fibre design after a La_0.2Sr_0.8Co_0.8Fe_0.2O_3?δ (LSCF) cathode was deposited by slurry coating and co-fired at 1200 °C. Anodes prepared by Ni electroless plating on YSZ electrolytes (discs and hollow fibres) sintered at lower temperature (1000–1200 °C) benefited from a greater Ni penetration compared to electrolytes sintered at 1400 °C. Further increases in anode porosity and performance were achieved by anode oxidation in air at 1200–1400 °C, followed by reduction in H₂ at 800 °C.     

Performance and durability of Ni-coated YSZ anodes for intermediate temperature solid oxide fuel cells

NiO-coated YSZ composite powders were synthesized through the Pechini process in order to improve the performance and durability of SOFC anodes. Their microstructures and electrical properties have been investigated with thermal and redox cycling tests. The coverage of NiO crystals on the YSZ surface could be modulated by controlling the composition of the reaction mixture and the ratio of NiO and YSZ. Ni–YSZ electrodes were manufactured by sintering the die-pressed NiO–YSZ pellet at 1400 °C for 3 h, followed by reducing it to 800 °C under hydrogen atmosphere. The anode made from NiO/YSZ composite powder, which has a high homogeneity and plenty of contact sites between Ni and YSZ, has an excellent tolerance against thermal and redox cycling. The maximum power density of a single cell made from NiO/YSZ composite powder was 0.56 W cm^− 2 at 800 °C in reactive gases of humidified hydrogen and air. It can be concluded that the functional NiO/YSZ composite powder will suppress the degradation of anodes and enhance the long-term and redox stability of the unit cell at elevated temperatures.     

Effect of sintering temperature on the elemental diffusion and electrical conductivity of SrTiO<Subscript>3</Subscript>/YSZ composite ceramic

The 50 vol% SrTiO₃/yttria-stabilized zirconia (YSZ) composite ceramic was prepared through powder sintering route in 1400～1500 °C. Only the cubic YSZ and SrTiO₃ phases are detected in all the sintered ceramics, and the typical XRD peak positions of both phases have varied dramatically. The grain sizes and relative densities of all specimens increase evidently with the sintering temperature. The width of the SrTiO₃/YSZ interfacial region increases from 100.4 to 468.8 nm as the sintering temperature rises from 1400 to 1500 °C. The total electrical conductivities of the sample sintered at 1500 °C are remarkably higher than those at 1400 and 1450 °C, while the ion transference numbers drop from 0.837 to 0.731 with sintering temperature from 1400 to 1500 °C. The variations in the electrical properties above can be interpreted based on the effects of sintering temperature on the elemental diffusions during the sintering process.     

Structural and electrical properties of ZnO-doped 8 mol% yttria-stabilized zirconia

8 mol% Yttria-stabilized zirconia (8YSZ) powder was prepared by coprecipitation. ZnO (0.5, 1.0, 2.0, 5.0, 10.0 wt.%) was added to the YSZ powder through a mechanical mixing method. The densification , microstructure and electrical properties of the YSZ ceramics sintered at 1300 °C for 2 h, were investigated. It was found that the small addition of ZnO was effective in reducing the sintering temperature and promoting the densification rate of the ceramics. The 5.0 wt.% ZnO-doped YSZ has ∼ 96% relative density, as compared to ∼ 89% relative density for the undoped sample. The total conductivity of 8YSZ was evidently increased by doping small amount of ZnO. For the 0.5 wt.% doped sample, the total conductivity of 2.89 × 10^− 2 Ω^− 1 cm^− 1 and an increase of 120% in conductivity were observed at 800 °C, as compared to that of the undoped one. We also found that the grain boundary (GB) conductivity could be improved by small addition of ZnO. At intermediate temperature (∼ 300 °C), the maximum enhancement of GB conductivity was observed with 5.0 wt% ZnO dopant. Finally, the volume percentage of GB in the ceramics was estimated by the brick layer model. The possible mechanism related to the improved GB conduction of the YSZ due to the ZnO additions was discussed.     

Microstructure-property relations in composite yttria-substituted zirconia solid electrolytes

A study of composite 8 mol% yttria stabilized zirconia (8YSZ) and 3 mol% yttria tetragonal zirconia polycrystal (3YTZP) solid electrolytes sintered under isothermal and two-step sintering cycles is reported. The nominal phase composition is retained for composites with up to 25 wt.% 3YTZP. These composites show a combination of beneficial effects with respect to pure 8YSZ, including slight improvement in sinterability, gains in bulk and grain boundary conductivity and also enhanced fracture toughness. Impedance spectroscopy revealed an enhancement of the specific grain boundary conductivity for samples with finer grain sizes, attained by increasing the fraction of 3YTZP or by hindering grain growth under two-step sintering cycles. This effect is rationalized in terms of a decrease of the grain boundary space-charge potential. The conductivity gains decrease with increasing temperature, but even at 700 °C the total ionic conductivity of ceramics with 25 wt.% 3YTZP is still higher than that of pure 8YSZ, whereas at 900 °C there is a performance loss of less than 10%. The improved mechanical and electrical performance in the intermediate temperature range represents an important advantage of the heterostructured electrolytes for low/intermediate temperature SOFC operation.     

Sulfur/microporous carbon composites for Li-S battery

A commercial carbon black with microporous framework is used as carbon matrix to prepare sulfur/microporous carbon (S/MC) composites for the cathode of lithium sulfur (Li-S) battery. The S/MC composites with 50, 60, and 72 wt.% sulfur loading are prepared by a facile heat treatment method. Electrochemical performance of the as-prepared S/MC composites are measured by galvanostatic charge/discharge tests, cyclic voltammetry (CV), and electrochemical impedance spectroscopy (EIS), with carbonate-based electrolyte of 1.0 M LiPF₆/(PC-EC-DEC). The composite with 50 wt.% sulfur presents the optimized electrochemical performance, including the utilization of active sulfur, discharge capacity, and cycling stability. At the current density of 50 mA g^?1, it can demonstrate a high initial discharge capacity of 1624.5 mAh g^?1. Even at the current density of 800 mA g^?1, the initial capacity of 1288.6 mAh g^?1 can be obtained, and the capacity can still maintain at 522.8 mAh g^?1 after 180 cycles. The remarkably improved electrochemical performance of the S/MC composite with 50 wt.% sulfur are attributed to the carbon matrix with microporous structure, which can effectively enhance the electrical conductivity of the sulfur cathode, suppress the loss of active material during charge/discharge processes, and restrain the migration of polysulfide ions to the lithium anode.     

Nanogravel structured NiO/Ni foam as electrode for high-performance lithium-ion batteries

Nanogravel structured NiO/Ni electrodes were fabricated by using two-step thermal oxidation method of commercial nickel (Ni) foam in air for lithium-ion batteries (LIBs). The macro- and micro-structures of the NiO/Ni foam were characterized using X-ray diffraction (XRD), scanning electron microscopy coupled with energy-dispersive X-ray spectroscopy (SEM-EDX), and Raman spectroscopy. Galvanostatic tests revealed that the electrode exhibits no obvious capacity fading over 40 cycles at 1 C (718 mAg^?1) and 2.5 C (1.8 Ag^?1) current rate. The discharge capacity was higher than the theoretical capacity of NiO even at a high-current rate of 2.5 C. The electrodes can deliver a reversible capacity of 1116.65 mAh g^?1 after 20th cycle at 1 C rate and 1026.20 mAh g^?1 after 40th cycle at 2.5 C rate. The cyclic voltammograms and impedance spectra analysis indicated that a redox reaction of NiO–Ni⁰ with formation and decomposition of Li₂O. The excellent electrochemical performance is mainly attributed to the nanogravel structure of the NiO/Ni foam electrodes as well as its excellent electrical contact between NiO and Ni. The unique nanostructured NiO on the highly conductive metallic Ni in core resulted in the enhanced discharge capacity, coulombic efficiency, cyclic stability, and rate capability when utilized as negative electrodes in LIBs.     

Preparation of YSZ films by magnetron sputtering for anode-supported SOFC

YSZ films for anode-supported SOFCs were prepared by reactive sputtering method. It was found that the surface morphology of anode substrate has a very important effect on the quality of sputtered films. By applying an anode functional layer and making the anode surface smooth, dense and uniform YSZ films of 10 µm in thickness were successfully fabricated. The sintering behaviors of the sputtered YSZ films were also discussed. It is suggested that the optimized densification condition for the deposited YSZ films is sintering at 1250 °C for 4 h. Single cells with sputtered YSZ film as electrolyte and LSM-YSZ as active cathode materials were tested. 1.08 V open circuit voltage and a 700 mW/cm² maximum power density were achieved at 750 °C by using humidified H₂ as fuel and air as oxidant.     

Reaction between solid oxide fuel cell materials

In fabrication processes of solid oxide fuel cells, high-temperature heat treatments cannot be avoided. It will give rise to mutual reaction and interdiffusion of the cell component materials: yttria-stabilized zirconia (YSZ, electrolyte), (La, Sr)MnO₃ (cathode), Ni-YSZ cermet (anode) and (La, Ca)CrO₃ (separator). Reactivity of LaMnO₃ and YSZ was estimated by thermodynamic calculations, and it was found that the nonstoichiometry at La site in LaMnO₃ plays an important role on the reaction. Diffusion of Mn into YSZ leads to increase of La activity at the interface and promotes the reaction. Electrical conductivity of YSZ decreases when Mn dissolves in the cubic phase of YSZ. Oxidation state of the dissolving Mn varies with partial pressure of oxygen and affects the electrical properties of YSZ. Migration of Ca from (La, Ca)CrO₃ separator to other cell components is one of the largest problems in the co-firing cell fabrication process because it prohibits the sintering of the separator.     

Titania doped YSZ for SOFC anode Ni-cermet

The influence of doping YSZ (8 mol%YttriaStabilizedZirconia) with 5 and 10 mol% TiO₂ on the electrical conductivity and the microstructure was examined for different YSZ-Ni cermets as a function of Ni-content. For the 5 mol%TiO₂-doped cermets the electrical conductivity was always better than that of the undoped, exhibiting a lower degradation rate at 1000 °C. Microstructure examination of the samples showed a lower tendency for agglomeration of the Ni-particles of the doped cermets compared to the Ni/YSZ cermet. The 10 mol%TiO₂-doped cermets exhibited lower conductivity values and this was attributed to the significantly higher porosity which resulted from a reaction taking place during sintering between the insoluble TiO₂ in YSZ and NiO. This reaction results in the formation of a NiO-TiO₂ spinel phase, which leads to the expansion of the samples causing microstructural defects. Paper presented at the 6th Euroconference on Solid State Ionics, Cetraro, Calabria, Italy, Sept. 12–19, 1999.     

Improvement of plasma-sprayed YSZ electrolytes for solid oxide fuel cells by alumina addition

Atmospheric plasma spray is a fast and economical process for deposition of yttria-stabilized zirconia (YSZ) electrolyte for solid oxide fuel cells. YSZ powders have been used to prepare plasma-sprayed thin ceramic films on the metallic substrate employing plasma spray technology at atmospheric pressure. Alumina doping was employed to improve the structural characteristics and electrical properties of YSZ. The effect of alumina addition from 1 to 5 wt.% on the properties of plasma-sprayed YSZ films was investigated. It was found that the gas permeability of the Al-doped YSZ electrolyte layer reached a level of 8.6 × 10⁻⁷ cm⁴ gf⁻¹ s⁻¹, which is a necessary value for the practical operation of solid oxide fuel cells. Alumina doping considerably increased the ionic conductivity of plasma-sprayed YSZ. The open circuit voltage of the alumina-doped YSZ coating was approximately equal to the theoretical value for dense YSZ material.     

Red phosphorus encapsulated in porous carbon derived from cigarette filter solid waste as a promising anode material for lithium-ion batteries

Red phosphorus (RP) is considered to be one of the promising anode materials for lithium-ion batteries (LIBs) on account of its high theoretical capacity (2596 mAh g^?1), abundant resources, and environmental friendliness. However, the intrinsic insulating nature and large volume change during lithium insertion/extraction process lead to drastic capacity loss upon cycling. Recently, great attention has been devoted to constructing P-based composites via mixing with carbon materials. Here, a novel P/C composite, in which red P nanoparticles were homogeneously distributed in cigarette filter-derived porous carbon (CPC), was fabricated by vaporization-condensation method. Due to the unique characteristics of porous carbon, including high specific area, good conductivity, and rich internal porous structure, CPC obtained by means of heat treatment that serves as conductive matrix to load red P could be of great benefits, which can not only improve the overall electrical conductivity but also mitigate the volume expansion issues. As a result, the RP/CPC composite as an anode material for LIBs delivers a good cycling stability (500 mAh g^?1 at 100 mA g^?1 with a high Coulombic efficiency above 99% after 50 cycles) and rate capability (355 mAh g^?1 even at 1000 mA g^?1).     

Influence of YSZ electrolyte thickness on the characteristics of plasma-sprayed cermet supported tubular SOFC

Novel Ni–Al₂O₃ cermet-supported tubular SOFC cell was fabricated by thermal spraying. Flame-sprayed Al₂O₃–Ni cermet coating played dual roles of a support tube and an anode current collector. Y₂O₃-stabilized ZrO₂ (YSZ) electrolyte was deposited by atmospheric plasma spraying (APS) to aim at reducing manufacturing cost. The gas tightness of APS YSZ coating was achieved by post-densification process. The influence of YSZ coating thickness on the performance of SOFC test cell was investigated in order to optimize YSZ thickness in terms of open circuit voltage of the cell and YSZ ohmic loss. It was found that the reduction of YSZ thickness from 100 μm to 40 μm led to the increase of the maximum output power density from 0.47 W/cm² to 0.76 W/cm² at 1000 °C. Using an APS 4.5YSZ coating of about 40 μm as the electrolyte, the test cell presented a maximum power output density of over 0.88 W/cm² at 1030 °C. The results indicate that SOFCs with thin YSZ electrolyte require more effective cathode and anode to improve performance.     

Flexible carbon nanostructures with electrospun nickel oxide as a lithium-ion battery anode

Carbon nanostructures (CNS) with high electrical conductivity and unique branched structure of carbon nanotubes combined with NiO nanofibers (NFs) were used as anode for lithium-ion batteries. CNS works as a framework substrate for the anodic conversion reaction of nickel oxide (NiO). Electrochemical performance and behavior of CNS/NiO anodes is compared with the conventional carbon (C)/NiO anodes. CNS/NiO NF-based anode retains high specific capacity under different current densities compared to C/NiO anode. Moreover, specific capacity as high as 450 mAh/g for CNS/NiO NF anode is observed compared to only 90 mAh/g for C/NiO NFs using a current density of 500 mA/g after 500 cycles. This improved performance is attributed to the highly conductive network of CNS leading to efficient charge transfer. The high porosity, electrical conductivity as well as the branched and networked nature of CNS reveal to be of critical importance to allow the electrochemical conversion reactions.