Solid oxide fuel cells (SOFCs) are promising electrochemical devices that enable the highest fuel-to-electricity conversion efficiencies under high operating temperatures. The concept of multi-stage electrochemical oxidation using SOFCs has been proposed and studied over the past several decades for further improving the electrical efficiency. However, the improvement is limited by fuel dilution downstream of the fuel flow. Therefore, evolved technologies are required to achieve considerably higher electrical efficiencies. Here we present an innovative concept for a critically-high fuel-to-electricity conversion efficiency of up to 85% based on the lower heating value (LHV), in which a high-temperature multi-stage electrochemical oxidation is combined with a proton-conducting solid electrolyte. Switching a solid electrolyte material from a conventional oxide-ion conducting material to a proton-conducting material under the high-temperature multi-stage electrochemical oxidation mechanism has proven to be highly advantageous for the electrical efficiency. The DC efficiency of 85% (LHV) corresponds to a net AC efficiency of approximately 76% (LHV), where the net AC efficiency refers to the transmission-end AC efficiency. This evolved concept will yield a considerably higher efficiency with a much smaller generation capacity than the state-of-the-art several tens-of-MW-class most advanced combined cycle (MACC).

Long-term performance testes by CRIEPI (Central Research Institute for Electric Power Industry) on six industrial stacks have revealed an interesting correlation between cathode polarization loss and ohmic loss. To make clear the physicochemical meaning of this correlation, detailed analyses were made on the conductivity degradation of YSZ electrolyte in button cells and then on the ohmic losses in the industrial cells in terms of time constants which are determined from speed of the tetragonal transformation through the Y diffusion from the cubic phase to the tetragonal phase. In some cases, shorter time constants (faster degradations) were detected than those expected from the two-time-constant (with and without NiO reduction effects) model, suggesting that additional ohmic losses after subtracting the contribution from the tetragonal transformation must be caused from other sources such as cathode-degradation inducing effects. Main cathode degradations can be ascribed to sulfur poisoning due to contamination in air in the CRIEPI test site. An important feature was extracted as this cathode degradations became more severe when the gadolinium-doped ceria (GDC) interlayers were fabricated into dense film. Plausible mechanisms for cathode degradations were proposed based on the Sr/Co depletion on surface of lanthanum strontium cobalt ferrite (LSFC) in the active area. Peculiar cathode degradations found in stacks are interpreted in term of changes in surface concentration by reactions with sulfur oxide, electrochemical side reactions for water vapor emission or Sr volatilization, and diffusion of Sr/Co from inside LSCF.

Previously, most studies of proton-conductive electrolytes for SOFCs were conducted to achieve lower-temperature operation. In this study, we investigate a proton-conductive electrolyte to realize high-efficiency SOFCs. To this end, the dependencies of the total conductivity of Ba(Zr 0.1 Ce 0.7 Y 0.1 Yb 0.1)O 3-δ on the oxygen partial pressure and temperature under wet and dry conditions were measured. Based on the measurement data, we analyzed the ratio of ionic current density to electronic current density in the temperature range of 550-900°C. Assuming that the area-specific resistance of the electrolyte and the external current density were 0.383 Ωcm 2 and 0.25 Acm-2 , respectively, the leakage current densities caused by the minority carriers were calculated to be 5.7% and 10.2% of the external current density at 550°C and 600°C, respectively. This study developed a method to evaluate proton-conductive electrolyte materials and established guidelines for the development of new materials for high-efficiency SOFCs.