Fabrication of a large area cathode-supported thin electrolyte film for solid oxide fuel cells via tape casting and co-sintering techniques

A large area cathode-supported electrolyte film, comprising porous (La_0.8Sr_0.2)_0.95MnO₃ (LSM95) cathode substrate, LSM95/Zr_0.89Sc_0.1Ce_0.01O_2?x (SSZ) cathode active layer, and SSZ electrolyte, has been successfully fabricated by tape casting and co-sintering techniques. The interface reaction between cathode and electrolyte was inhibited by using A-site deficient LSM. A dense enough SSZ thin film with a thickness of ～26 μm was obtained at 1250 °C. By using Pt as anode, the obtained single cell reached the maximum power density of 0.54 W cm^?2 at 800 °C in O₂/humidified H₂, with open circuit voltage (OCV) value of 1.08 V.     

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.     

Cost-effective solid oxide fuel cell prepared by single step co-press-firing process with lithiated NiO cathode

A cost-effective cell fabrication process was developed for intermediate temperature solid oxide fuel cells (IT-SOFCs). Co-doped ceria Ce_0.8Gd_0.05Y_0.15O_1.9 (GYDC) was synthesized by carbonate co-precipitation method. Lithiated NiO was prepared by glycine-nitrate combustion method and adopted as cathode material for IT-SOFCs. Single cell was fabricated by one-step dry-pressing and co-firing anode, anode functional layer (AFL), electrolyte and cathode together at 1200 °C for 4 h. The cell presented decent performance and an overall electrode polarization resistance of 0.54 Ω cm² has been achieved at 600 °C. These results demonstrate the possibility of using lithiated NiO as cathode material for ceria-based IT-SOFCs and the development of affordable fuel cell devices is encouraged.     

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.     

Barium carbonate nanoparticle as high temperature oxygen reduction catalyst for solid oxide fuel cell

BaCO₃ nanoparticles are demonstrated as outstanding electrocatalysts to enhance the high temperature oxygen reduction reaction (ORR) in solid oxide fuel cells (SOFCs). BaCO₃ nanoparticles are formed from thermal decomposition of barium acetate, Ba(Ac)₂ infiltrated to porous cathode skeleton and shows good chemical compatibility with cathode materials. BaCO₃ nanoparticles can greatly reduce the area specific resistance (ASR) of typical SOFC cathode materials, including La_0.8Sr_0.2FeO_3 -δ (LSF), La_0.6Sr_0.4Co_0.2Fe_0.8O_3 -δ (LSCF) and La_0.8Sr_0.2MnO_3 -δ (LSM). For example at 700 °C, ASR for LSF on yttria-stabilized zirconia (YSZ) electrolyte decreases from 2.95 Ω cm² to 0.77 Ω cm² when 12.9 wt.% BaCO₃ nanoparticles are deposited on the surface of the porous LSF electrode. Impedance spectra analysis shows that the decrease in ASR mainly comes from the reduction of the low frequency resistance. Furthermore, BaCO₃ nanoparticles are found to greatly enhance the oxygen chemical exchange coefficient. Most importantly, it has been found that the catalytic activity of BaCO₃ nanoparticles is even higher than those of the precious metals such as Pd, Rh, Pt and Ag, infiltrated into LSF, LSCF and LSM electrodes supported on YSZ electrolytes.     

Fabrication by Co-extrusion and electrochemical characterization of micro-tubular hollow fibre solid oxide fuel cells

A phase inversion process was used to co-extrude cerium–gadolinium oxide (Ce_0.9Gd_0.1O_1.95)/NiO–CGO dual-layer hollow fibres (HF), which were then sintered to form, respectively, the electrolyte and high porosity anode precursor of a solid oxide fuel cell (SOFC) with anode inner diameter of 0.8 mm. Graded CGO–lanthanum strontium cobalt ferrite (La_0.6Sr_0.4Fe_0.8Co_0.2O₃) cathode layers were then painted onto the CGO electrolyte to form a micro-tubular HF-SOFC. With a carefully designed anode current collector, this produced maximum power densities of 1186–5864 W m^? 2 at 450–570 °C. High magnification imaging analysis revealed large three-phase boundary regions within the anode, a dense electrolyte layer and clearly highlighted the multiple CGO–LSCF cermet and pure LSCF cathode layers. The performance of the HF-SOFC with a twenty millimetre active length showed no degradation after four thermal cycles between 300 °C and 570 °C.     

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.     

Impact of reforming catalyst on the anodic polarisation resistance in single-chamber SOFC fed by methane

This paper emphasises the electrochemical and catalytic properties of a Ni–10% GDC (10% gadolinium-doped ceria) cermet anode of a single-chamber solid oxide fuel cell (SC-SOFC). Innovative coupling of electrochemical impedance spectroscopy with gas chromatography measurements was carried out to characterise the anode material using an operando approach. The experiments were conducted in a symmetric anode/electrolyte/anode cell prepared by slurry coating resulting in 100 μm-thick anode layers. The electrochemical performance was assessed using a two-electrode arrangement between 400 °C and 650 °C, in a methane-rich atmosphere containing CH₄, O₂ and H₂O in a 14:2:6 volumetric ratio. The insertion of a Pt–CeO₂ based catalyst with high specific surface area inside the cermet layer was found to promote hydrogen production from the Water Gas Shift reaction and consequently to improve the electrochemical performances. Indeed, a promising polarisation resistance value of 12 Ω cm² was achieved at 600 °C with a catalytic loading of only 15 wt.%.     

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.     

Fabrication and characterization of large-size electrolyte/anode bilayer structures for low-temperature solid oxide fuel cell stack based on gadolinia-doped ceria electrolyte

Preliminary progress is reported in this communication in building a planar anode-supported low-temperature solid oxide fuel cell (SOFC) stack based on gadolinia-doped ceria (GDC) electrolyte, i.e. fabrication and characterization of a Ø80 planar bilayer structure composed of GDC electrolyte film and Ni–GDC anode substrate. The anode substrates were prepared from mixtures of NiO, GDC, and carbon black by die-pressing. After pre-firing to remove the carbon black, the anode substrates were deposited with a GDC layer using a spray coating technique. The green bilayers of anode substrate and electrolyte film were then co-sintered at 1500 °C for 3 h. Through proper control of the sintering process, bilayer structures with excellent flatness were achieved after co-sintering. Scanning electron microscopy (SEM) observation indicated that the electrolyte film was about 22 μm in thickness, highly dense, crack-free, and well-bonded to the anode substrate. Small disks which were cut out from the Ø80 bilayer structure were electrochemically examined in a single button-cell mode incorporating a (LaSr)(CoFe)O₃–GDC composite cathode. With humidified hydrogen as the fuel and air as the oxidant, the cell demonstrated an open-circuit voltage of 0.884 V and a maximum power density of 562 mW/cm² at 600 °C. The results imply that high-quality anode-supported electrolyte/anode bilayer structures were successfully fabricated. Based on them, planar anode-supported SOFC stacks will be assembled in the future.     

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.     

Improved electrochemical performance of SrCo0.8Fe0.2O3−δ–La0.45Ce0.55O2−δ composite cathodes for IT-SOFC

The performance of the SrCo_0.8Fe_0.2O_3−δ(SCF)–La_0.45Ce_0.55O_2−δ(LDC) composite cathodes was studied in this paper. The composite cathodes were prepared by screen-printing, and then sintered at 1200 °C for 2 h. Electrochemical impedance spectroscopy (EIS) and cathodic polarization test were carried out to investigate the electrochemical properties of the composite cathodes. The results showed that the composite cathodes had superior electrochemical performance compared to that of the pure SCF cathodes. Through optimizing the structures of composite cathodes, the cathodic overpotential of triple-layer SCF–LDC composite cathodes was only 23 mV at 0.3 A cm⁻². The specific ohmic resistance, charge transfer resistance and gas phase diffusion resistance of the triple-layer SCF–LDC cathodes were the lowest for the SCF–LDC composite cathodes, and they were 0.1 Ω cm², 0.01 Ω cm² and 0.1 Ω cm² respectively at 800 °C. The changes were attributable to the enlargement of triple phases boundary (tpb) and enhancement of the adhesion between electrode and electrolyte by adding LDC to the cathode material.     

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.     

Development of micro-tubular SOFCs with an improved performance via nano-Ag impregnation for intermediate temperature operation

Micro-tubular solid-oxide fuel cell consisting of a 10-μm thick (ZrO₂)_0.89(Sc₂O₃)_0.1(CeO₂)_0.01 (ScSZ) electrolyte on a support NiO/(ScSZ) anode (1.8 mm diameter, 200 μm wall thickness) with a Ce_0.8Gd_0.2O_1.9 (GDC) buffer-layer and a La_0.6Sr_0.4Co_0.2Fe_0.8O_3−δ (LSCF)/GDC functional cathode has been developed for intermediate temperature operation. The functional cathode was in situ formed by impregnating the well-dispersed nano-Ag particles into the porous LSCF/GDC layer using a citrate method. The cells yielded maximum power densities of 1.06 W cm⁻² (1.43 A cm⁻², 0.74 V), 0.98 W cm⁻² (1.78 A cm⁻², 0.55 V) and 0.49 W cm⁻² (1.44 A cm⁻², 0.34 V), at 650, 600 and 550 °C, respectively.     

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 solid oxide fuel cells with electrocatalytically enhanced (La,Sr)MnO3 cathodes

The conventionally mixed LSM–YSZ, LSM impregnated YSZ (LSM + YSZ) and Pd impregnated LSM–YSZ (Pd + LSM–YSZ) cathodes, were prepared and evaluated by electrochemical impedance spectroscopy and single cell testing. The electrochemical performance of the impregnated cathodes have been significantly boosted due to the formation of nano-sized LSM and Pd particles on the YSZ and LSM–YSZ substrates, respectively, and in turn, the increased area of the triple phase boundary (TPB) where the O₂ reduction reaction occurs, the power densities as high as 1.42 and 0.83 W cm^?2 at 750 °C were achieved from single cells with the Pd + LSM–YSZ and LSM + YSZ cathodes, respectively, in contrast to 0.20 W cm^?2 from the single cell with the conventional LSM–YSZ cathode. Suggesting the Pd + LSM–YSZ and LSM + YSZ cathodes can be well used for the intermediate temperature solid oxide fuel cells (IT-SOFCs).     

Preparation of an extremely dense BaCe0.8Sm0.2O3−δ thin membrane based on an in situ reaction

The thin membrane of BaCe_0.8Sm_0.2O_3−δ (BCS) with high quality was successfully fabricated on porous NiO–BCS anode substrate through a novel in situ reaction method. The key part of this method is to directly spray well-mixed suspension of BaCO₃, CeO₂ and Sm₂O₃ instead of pre-synthesized BCS ceramic powder on the anode substrate. After sintering at 1400 °C for 5 h, the extremely dense electrolyte membrane in the thickness of 10 μm is obtained. A single cell was assembled with La_0.7Sr_0.3FeO_3−σ as cathode and tested with humidified hydrogen as fuel at 650 °C. The open circuit voltage (OCV) and maximum power density respectively reach 1.04 V and 535 mW/cm². Interface resistance of cell under open circuit condition was also investigated.     

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.     

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.     

Electrode properties of Sr doped La2CuO4 as new cathode material for intermediate-temperature SOFCs

High performance La_2−xSr_xCuO_4−δ (x = 0.1, 0.3, 0.5) cathode materials for intermediate temperature solid oxide fuel cell (IT-SOFCs) were prepared and characterized. The investigation of electrical properties indicated that La_1.7Sr_0.3CuO₄ cathode has low area specific resistance (ASR) of 0.16 Ω cm² at 700 °C and 1.2 Ω cm² at 500 °C in air. The rate-limiting step for oxygen reduction reaction on La_1.7Sr_0.3CuO₄ electrode changed with oxygen partial pressure and measurement temperature. La_1.7Sr_0.3CuO₄ cathode exhibits the lowest overpotential of about 100 mV at a current density of 150 mA cm⁻² at 700 °C in air.