3D printing of reversible solid oxide cell stacks for efficient hydrogen production and power generation

Abstract

Renewable hydrogen offers a promising pathway to address the challenge of large-scale chemical energy storage in the transition to a decarbonized future. The most efficient devices to convert renewable electricity into hydrogen, and vice versa, are reversible solid oxide cells (SOC-s). Despite recent advances in materials performance and durability, conventional ceramic manufacturing technologies strongly limit the huge potential of SOC-s, imposing severe geometrical restrictions that penalize the overall system efficiency. Here we capture the benefits of using previously unexplored complex-shapes by scaling 3D-printed reversible solid oxide cells with improved mechanical properties, higher performance, and embedded functionality. Stacks made of 45 cm2-3D-printed electrolyte-supported solid oxide cells combined with ultrathin flat metallic interconnects were successfully fabricated and operated in fuel cell (SOFC) and electrolysis (SOEC) modes delivering up to 85 L/h of hydrogen production while presenting less than 5 % degradation after more than 500 h of operation. The advances presented here demonstrate the viability of upscaling the process of solid-oxide-cell 3D printing and brings advantageous stack designs aimed for a cost-competitive and customizable hydrogen technologies deployment. In particular, the enhancement by design achieved here provides innovative SOC stacks with volumetric and gravimetric power densities that are three and four times higher, respectively, than their planar counterparts using the same set of materials.