Freeze-casting for the fabrication of solid oxide fuel cells: A review

Du, Yanhai; Hedayat, Nader; Panthi, Dhruba; Ilkhani, Hoda; Emley, Benjamin; Woodson, Theo

doi:10.1016/j.mtla.2018.07.005

Cited by 42 publications

(24 citation statements)

References 101 publications

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“…Hierarchically porous ceramics with aligned and directional pores were recently made using freeze-casting and freeze-drying, particularly for the fabrication of solid oxide fuel cells [194]. An aqueous-processed LFP cathode for LIBs has also been made using freezespraying and freeze-drying [90].…”

Section: Freeze-coating and Freeze-dryingmentioning

confidence: 99%

Opportunities for the State-of-the-Art Production of LIB Electrodes—A Review

Bryntesen¹,

Strømman²,

Tolstorebrov³

et al. 2021

Energies

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A sustainable shift from internal combustion engine (ICE) vehicles to electric vehicles (EVs) is essential to achieve a considerable reduction in emissions. The production of Li-ion batteries (LIBs) used in EVs is an energy-intensive and costly process. It can also lead to significant embedded emissions depending on the source of energy used. In fact, about 39% of the energy consumption in LIB production is associated with drying processes, where the electrode drying step accounts for about a half. Despite the enormous energy consumption and costs originating from drying processes, they are seldomly researched in the battery industry. Establishing knowledge within the LIB industry regarding state-of-the-art drying techniques and solvent evaporation mechanisms is vital for optimising process conditions, detecting alternative solvent systems, and discovering novel techniques. This review aims to give a summary of the state-of-the-art LIB processing techniques. An in-depth understanding of the influential factors for each manufacturing step of LIBs is then established, emphasising the electrode structure and electrochemical performance. Special attention is dedicated to the convection drying step in conventional water and N-Methyl-2-pyrrolidone (NMP)-based electrode manufacturing. Solvent omission in dry electrode processing substantially lowers the energy demand and allows for a thick, mechanically stable electrode coating. Small changes in the electrode manufacturing route may have an immense impact on the final battery performance. Electrodes used for research and development often have a different production route and techniques compared to those processed in industry. The scalability issues related to the comparison across scales are discussed and further emphasised when the industry moves towards the next-generation techniques. Finally, the critical aspects of the innovations and industrial modifications that aim to overcome the main challenges are presented.

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Section: Freeze-coating and Freeze-dryingmentioning

confidence: 99%

Opportunities for the State-of-the-Art Production of LIB Electrodes—A Review

Bryntesen¹,

Strømman²,

Tolstorebrov³

et al. 2021

Energies

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“…Both freeze casting and phase-inversion-assisted tape casting have been utilized to fabricate gas separation membranes [155][156][157] as well as supports for SOFCs and SOECs. [158][159][160][161][162] The basic principle of freeze casting is the formation of a very specific pore morphology through the directional freezing of the liquid phase in the slurry, and its subsequent sublimation. The main application of freeze casting using tape-cast ceramic powder suspensions is unidirectional freezing, where the tape is brought into contact with a cold surface on one side that removes sufficient heat from the tape to freeze the solvent.…”

Section: Tailoring Porosity In the Green Layermentioning

confidence: 99%

“…Both freeze casting and phase‐inversion‐assisted tape casting have been utilized to fabricate gas separation membranes [ 155–157 ] as well as supports for SOFCs and SOECs. [ 158–162 ]…”

Section: Wet Processing Of Zirconia Filmsmentioning

confidence: 99%

Tuning the Microstructure and Thickness of Ceramic Layers with Advanced Coating Technologies Using Zirconia as an Example

et al. 2020

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“…When the sample is completely frozen, it is dried via sublimation to remove the solvent and obtain a porous structure. Since the pores created in this method are a replica of the solvent crystals formed during freezing, unidirectional freezing results in unidirectional and continuously graded macroporous channels . Consequently, freeze casting is capable of producing porous structures with a tortuosity approaching unity, whereas conventionally fabricated porous ceramics have a tortuosity ranging from 3 to 10 .…”

Section: Introductionmentioning

confidence: 99%

“…Since the pores created in this method are a replica of the solvent crystals formed during freezing, unidirectional freezing results in unidirectional and continuously graded macroporous channels. 20,21 Consequently, freeze casting is capable of producing porous structures with a tortuosity approaching unity, whereas conventionally fabricated porous ceramics have a tortuosity ranging from 3 to 10. 22 As a processing method, freeze casting offers a number of advantages such as simple sintering without burning out pore formers, wide range of porosity controllable by the solids loading of the suspension, compatibility with various types of materials, and cost-effective production.…”

Section: Introductionmentioning

confidence: 99%

Tubular solid oxide fuel cells fabricated by a novel freeze casting method

et al. 2019

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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.

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Freeze-casting for the fabrication of solid oxide fuel cells: A review

Cited by 42 publications

References 101 publications

Opportunities for the State-of-the-Art Production of LIB Electrodes—A Review

Opportunities for the State-of-the-Art Production of LIB Electrodes—A Review

Tuning the Microstructure and Thickness of Ceramic Layers with Advanced Coating Technologies Using Zirconia as an Example

Tubular solid oxide fuel cells fabricated by a novel freeze casting method

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