Design of next-generation ceramic fuel cells and real-time characterization with synchrotron X-ray diffraction computed tomography

Ceramic fuel cells offer a clean and efficient means of producing electricity through a variety of fuels. However, miniaturization of cell dimensions for portable device application remains a challenge, as volumetric power densities generated by readily-available planar/tubular ceramic cells are limited. Here, we demonstrate a concept of ‘micro-monolithic’ ceramic cell design. The mechanical robustness and structural integrity of this design is thoroughly investigated with real-time, synchrotron X-ray diffraction computed tomography, suggesting excellent thermal cycling stability. The successful miniaturization results in an exceptional power density of 1.27 W cm−2 at 800 °C, which is among the highest reported. This holistic design incorporates both mechanical integrity and electrochemical performance, leading to mechanical property enhancement and representing an important step toward commercial development of portable ceramic devices with high volumetric power (>10 W cm−3), fast thermal cycling and marked mechanical reliability

Design of next-generation ceramic fuel cells and real-time characterization with synchrotron X-ray diffraction computed tomography

Ceramic fuel cells offer a clean and efficient means of producing electricity through a variety of fuels. However, miniaturization of cell dimensions for portable device application remains a challenge, as volumetric power densities generated by readily-available planar/tubular ceramic cells are limited. Here, we demonstrate a concept of ‘micro-monolithic’ ceramic cell design. The mechanical robustness and structural integrity of this design is thoroughly investigated with real-time, synchrotron X-ray diffraction computed tomography, suggesting excellent thermal cycling stability. The successful miniaturization results in an exceptional power density of 1.27 W cm−2 at 800 °C, which is among the highest reported. This holistic design incorporates both mechanical integrity and electrochemical performance, leading to mechanical property enhancement and representing an important step toward commercial development of portable ceramic devices with high volumetric power (>10 W cm−3), fast thermal cycling and marked mechanical reliability

Highly-robust solid oxide fuel cell (SOFC): simultaneous greenhouse gas treatment and clean energy generation

Herein, results of combined greenhouse gas treatment with clean energy conversion is reported for the first time. Multi-channel tubular SOFCs were operated with N2O instead of air as the oxidant leading to a 50% increase in power density. Techno-economic evaluation suggested the feasibility of the combined approach eliminating the cost penalty for N2O abatement

Electrode design for direct-methane micro-tubular solid oxide fuel cells (MT-SOFC)

Herein, a micro-structured electrode design has been developed via a modified phase-inversion method. A thin electrolyte integrated with a highly porous anode scaffold has been fabricated in a single-step process and developed into a complete fuel cell for direct methane (CH4) utilisation. A continuous and well-dispersed layer of copper-ceria (Cu-CeO2) was incorporated inside the micro-channels of the anode scaffold. A complete cell was investigated for direct CH4 utilisation. The well-organised micro-channels and nano-structured Cu-CeO2 anode contributed to an increase in electrochemical reaction sites that promoted charge-transfer as well as facilitating gaseous fuel distribution, resulting in outstanding performances. Excellent electrochemical performances have been achieved in both hydrogen (H2) and CH4 operation. The power density of 0.16 Wcm−2 at 750 °C with dry CH4 as fuel is one of the highest ever reported values for similar anode materials

High-performance fuel cell designed for coking-resistance and efficient conversion of waste methane to electrical energy

Utilization or emission of low calorific value gases (LCVGs) containing <20% CH4 constitute economic and environmental challenges. Ceramic fuel cells offer a possible solution, but their performance is hindered by carbon formation ('coking'). Herein, we report a novel fuel cell designed to mitigate coking, yielding superior performances but using conventional commercially-available materials. The new micro-monolithic design has an extraordinary geometrical asymmetry that separates the mechanical support and anode current collector from the electrochemically active region and results in significantly facilitated mass transport, yielding power densities of 1.77-2.22 W cm-2 using LCVGs. In addition, the effluent containing only H2, CO and CO2 is of great industrial interest for methanol synthesis, if their ratios are adjusted appropriately. The new fuel cell developed was almost free from coke deactivation and was stable for over 500 h, indicating great promise for both efficient and environmentally benign use of LCVGs

High-performance fuel cell designed for coking-resistance and efficient conversion of waste methane to electrical energy

Utilization or emission of low calorific value gases (LCVGs) containing <20% CH4 constitute economic and environmental challenges. Ceramic fuel cells offer a possible solution, but their performance is hindered by carbon formation (‘coking’). Herein, we report a novel fuel cell designed to mitigate coking, yielding superior performances but using conventional commercially-available materials. The new micro-monolithic design has an extraordinary geometrical asymmetry that separates the mechanical support and anode current collector from the electrochemically active region and results in significantly facilitated mass transport, yielding power densities of 1.77–2.22 W cm−2 using LCVGs. In addition, the effluent containing only H2, CO and CO2 is of great industrial interest for methanol synthesis, if their ratios are adjusted appropriately. The new fuel cell developed was almost free from coke deactivation and was stable for over 500 h, indicating great promise for both efficient and environmentally benign use of LCVGs