Freeze casting is an established method for fabricating porous ceramic structures with controlled porosity and pore geometries. Herein, we developed a novel freeze casting and freeze drying process to fabricate tubular anode supports for solid oxide fuel cells (SOFCs). Freeze casting was performed by injecting aqueous anode slurry to a dual‐purpose freeze casting and freeze drying mold wrapped with peripheral coils for flowing a coolant. With the use of an ice barrier layer, proper control of the experimental setup, and adjustments in the drying temperature profile, complete drying of the individual anode tubes was achieved in 4 hours. The freeze‐cast anode tubes contained radially aligned columnar pore channels, thus significantly enhancing the gaseous diffusion. SOFC single cells with conventional Ni/yttria‐stabilized zirconia/strontium‐doped lanthanum manganite materials were prepared by dip coating the thin functional layers onto the anode support. Single cell tests showed that the concentration polarization was low owing to the highly porous anode support with directional pores. With H2/N2 (1:1) fuel, maximum power densities of 0.47, 0.36, and 0.27 W/cm2 were recorded at 800°C, 750°C, and 700°C, respectively. Our results demonstrate the feasibility of using freeze casting to obtain tubular SOFCs with desired microstructures and fast turn‐around times.
The use of freeze casting is suggested as a solution to significantly increase the volumetric power density of Tubular SOFCs (T-SOFCs) by enhancing gas diffusivity and triple phase boundary reactions. This paper reports the fabrication and characterization of freeze cast tubular anode supports for SOFCs. Tubular anode supports were fabricated using three methods: gelation casting, center pin method, and a freeze and drain method. A dual purpose freezing and drying chamber was designed and manufactured. The effects of slurry properties and process parameters were studied with respect to the resulting microstructures. The freeze and drain method was determined to be optimum for producing highly porous tubular anode supports with hierarchical, acicular or dendritic micro-pore channels. With an optimized freeze-drying cycle, drying time was reduced significantly with minimal residual moisture in the green bodies. Additionally, the electrochemical performance of the T-SOFCs with freeze cast anode was evaluated.
Increasing triple phase boundaries (TPBs) and reducing gas diffusion limitation in electrodes of solid oxide fuel cells (SOFCs) and solid oxide electrolysis cells (SOECs) have always been a goal for highly desirable electrochemical performance. Freeze-casting (also called ice-templating) is a promising method to produce hierarchically arranged porous ceramics with aligned and directional pores that could assist to reach such a goal. After reviewing the previous work on ceramic freeze-casting, we focused on optimizing the processes to better engineer tubular supports for SOFC as well as SOEC applications. Although the optimized process does not have too many constraints on the types of ceramic materials (except particle size and surface area), we selected the commonly used 8 mol.% yttria stabilized zirconia (8YSZ)/NiO composite material set as a starting point. Cast slurry formulations, cast temperatures, slurry feeding methods and freeze-drying conditions were studied. Microstructures of the tubular parts prepared at various conditions were examined. Finally, as an example for SOFC application, the fuel cell performance is reported.
Direct Internal Reforming (DIR) has potential to increase the value proposition of Solid Oxide Fuel Cells (SOFCs). Utilizing DIR in SOFCs, however, presents technical challenges. We believe the solution for achieving stable and efficient DIR in the SOFC requires an optimized anode microstructure that is tuned specifically for DIR. An aligned arrangement of hierarchical porosity in the fuel pathway, also while maintaining high surface area, is considered ideal and can be achieved via the freeze cast process. In this research, we present a method to manufacture and electrochemically evaluate tubular SOFCs (T-SOFCs). The freeze casted tubular anode was made and imaged with scanning electron microscopy and then evaluated after corresponding layers of electrolyte and cathode to form a complete electrochemical cell were added. A universal electrochemical performance testing fixture for T-SOFCs is also discussed with regards to facile methods of electrochemical evaluations of T-SOFCs.
scite is a Brooklyn-based organization that helps researchers better discover and understand research articles through Smart Citations–citations that display the context of the citation and describe whether the article provides supporting or contrasting evidence. scite is used by students and researchers from around the world and is funded in part by the National Science Foundation and the National Institute on Drug Abuse of the National Institutes of Health.
hi@scite.ai
10624 S. Eastern Ave., Ste. A-614
Henderson, NV 89052, USA
Copyright © 2024 scite LLC. All rights reserved.
Made with 💙 for researchers
Part of the Research Solutions Family.