Proton-Conducting Ceramics for Metal-Supported Solid Oxide Fuel Cells and Electrolysis Cells

Abstract

Proton conducting oxide electrolyte materials could potentially lower the operating temperature of metal-supported solid oxide cells (MS-SOCs) to the intermediate range 400 to 600 °C. The porous metal substrate provides the advantages of MS-SOCs such as high thermal and redox cycling tolerance, low-cost of structural materials, and mechanical ruggedness. The cell structure for fuel cell and electrolysis operation is shown in Figure 1. To incorporate proton-conductors into metal-supported cell configuration through co-sintering fabrication, a key factor is that the proton conductors must be compatible with reducing atmosphere sintering, as the porous metal substrate can not be fired in oxidizing atmosphere. In this work, viability of co-sintering fabrication of metal-supported proton conducting solid oxide cells is investigated. Candidate proton-conducting ceramics including perovskite-type oxides BaZr0.7Ce0.2Y0.1O3-δ (BZCY), SrZr0.5Ce0.4Y0.1O3-δ (SZCY), and Ba3Ca1.18Nb1.82O9-δ (BCN), pyrochlore-type oxides La1.95Ca0.05Zr2O7-δ (LCZ) and La2Ce2O7 (LCO), and acceptor doped rare-earth ortho-niobates La0.99Ca0.01NbO4 (LCN) were synthesized via solid state reactive synthesis or sol-gel synthesis. These ceramics are sintered at 1450°C in reducing environment alone and supported on Fe-Cr alloy metal support, and their key characteristics such as phase formation, sintering property, and chemical compatibility with metal support are determined. Most electrolyte candidates suffer from one or more challenges identified for this fabrication approach, including: phase decomposition in reducing atmosphere, evaporation of electrolyte constituents, contamination of the electrolyte with Si and Cr from the metal support, and incomplete electrolyte sintering. BZCY is particularly interesting because of its high proton conductivity, but it is found to suffer from reaction with Si and Cr present in the metal support, and loss of Ba via evaporation during sintering. Various approaches to overcome these limitations are proposed, and preliminary assessment indicates that the use of barrier layers, low-Si-content stainless steel, and sintering aids warrant further development. In contrast, La0.99Ca0.01NbO4 is found to be highly compatible with the metal support and co-sintering processing in reducing atmosphere, allowing dense electrolyte and porous electrode made of LCN to be co-sintered on porous stainless steel, Figure 2. A metal-supported cell is fabricated with La0.99Ca0.01NbO4 electrolyte, ferritic stainless steel support, Pt air electrode and nanoparticulate ceria-Ni hydrogen electrocatalyst. The total resistance is 50 Ω∙cm2 at 600 °C. This work clearly demonstrates the challenges, opportunities, and breakthrough of metal-supported proton-conducting solid oxide cells by co-sintering fabrication. Figure 1