Development of Novel 3D Cell Structure and Manufacturing Processes for Highly Efficient, Durable, and Redox Resistant Solid Oxide Electrolysis Cells

Abstract

A novel cell design and its corresponding manufacturing processes are being evaluated to demonstrate a highly efficient, durable, and reduction-oxidation (redox) resistant solid oxide electrolysis cell (SOEC) technology for hydrogen production. The cell design includes a unique 3D hydrogen electrode configuration composed of two layers ‒ a 3D hydrogen electrode support layer (for improved cell redox resistance) and an exsolved perovskite hydrogen electrode active layer (for enhanced cell performance and increased durability). The hydrogen electrode support layer consists of specifically designed 3D networks of electrode materials; tetragonal zirconia (TZ) and Ni-yttria stabilized zirconia (YSZ). Each phase is topologically connected throughout the electrode with controlled geometry and connectivity. The TZ component plays a role as an outer frame to provide structural support, while the Ni-YSZ component inside the TZ frame imparts electrical conductivity for the hydrogen electrode support layer. The hydrogen electrode active layer, which primarily supports electrochemical reaction, is a nickel-substituted perovskite that will exsolve nickel nanoparticles on the oxide surface when exposed to a reducing environment and is redox-reversible. A fabrication scheme being developed for this cell design incorporates a printing-based additive manufacturing (AM) process for producing the 3D hydrogen electrode. This paper presents the progress to date in developing the printing fabrication process for the 3D hydrogen electrode support and evaluating exsolved nickel-substituted perovskite for the hydrogen electrode active layer.