Highly durable, coking and sulfur tolerant, fuel-flexible protonic ceramic fuel cells.

Protonic ceramic fuel cells, like their higher-temperature solid-oxide fuel cell counterparts, can directly use both hydrogen and hydrocarbon fuels to produce electricity at potentially more than 50 per cent efficiency1,2. Most previous direct-hydrocarbon fuel cell research has focused on solid-oxide fuel cells based on oxygen-ion-conducting electrolytes, but carbon deposition (coking) and sulfur poisoning typically occur when such fuel cells are directly operated on hydrocarbon- and/or sulfur-containing fuels, resulting in severe performance degradation over time3-6. Despite studies suggesting good performance and anti-coking resistance in hydrocarbon-fuelled protonic ceramic fuel cells2,7,8, there have been no systematic studies of long-term durability. Here we present results from long-term testing of protonic ceramic fuel cells using a total of 11 different fuels (hydrogen, methane, domestic natural gas (with and without hydrogen sulfide), propane, n-butane, i-butane, iso-octane, methanol, ethanol and ammonia) at temperatures between 500 and 600 degrees Celsius. Several cells have been tested for over 6,000 hours, and we demonstrate excellent performance and exceptional durability (less than 1.5 per cent degradation per 1,000 hours in most cases) across all fuels without any modifications in the cell composition or architecture. Large fluctuations in temperature are tolerated, and coking is not observed even after thousands of hours of continuous operation. Finally, sulfur, a notorious poison for both low-temperature and high-temperature fuel cells, does not seem to affect the performance of protonic ceramic fuel cells when supplied at levels consistent with commercial fuels. The fuel flexibility and long-term durability demonstrated by the protonic ceramic fuel cell devices highlight the promise of this technology and its potential for commercial application.

The effect of grain size on the hydration of BaZr0.9Y0.1O3-δ proton conductor studied by ambient pressure X-ray photoelectron spectroscopy.

Three BaZr0.9Y0.1O3-δ (BZY10) pellets were prepared using different sintering processes, resulting in samples with different grain sizes, from 0.3 to 5 microns. Ambient pressure X-ray photoelectron spectra were recorded in argon, steam and oxygen atmospheres (100 mTorr) in the 300-500 °C temperature range. Deconvolution of O 1s peaks reveals 4 distinct contributions: sub-surface lattice oxide, termination layer oxides, OH- and gas-phase steam in wet environments. The OH- contribution of the O 1s peak includes sub-surface incorporation of protonic defects in the lattice related to hydration as well as surface hydroxylation and molecular water adsorption. The OH- concentration increases with grain size and with decreasing the analysis depth. These results suggest that grain boundaries associated with the larger grains adsorbed water more effectively. Thus, larger grains, which increase proton conductivity in BZY10, may also enhance catalytic activity for carbonaceous fuel oxidation by facilitating increased hydration and surface carbon removal.

Probing Grain-Boundary Chemistry and Electronic Structure in Proton-Conducting Oxides by Atom Probe Tomography.

A laser-assisted atom-probe-tomographic (LAAPT) method has been developed and applied to measure and characterize the three-dimensional atomic and electronic nanostructure at an yttrium-doped barium zirconate (BaZr0.9Y0.1O3-δ, BZY10) grain boundary. Proton-conducting perovskites, such as BZY10, are attracting intense interest for a variety of energy conversion applications. However, their implementation has been hindered, in part, because of high grain-boundary (GB) resistance that is attributed to a positive GB space-charge layer (SCL). In this study, LAAPT is used to analyze BZY10 GB chemistry in three dimensions with subnanometer resolution. From this analysis, maps of the charge density and electrostatic potential arising at the GBs are derived, revealing for the first time direct chemical evidence that a positive SCL indeed exists at these GBs. These maps reveal new insights on the inhomogeneity of the SCL region and produce an average GB potential barrier of approximately 580 mV, agreeing with previous indirect electrochemical measurements.

Interpreting equilibrium-conductivity and conductivity-relaxation measurements to establish thermodynamic and transport properties for multiple charged defect conducting ceramics.

A model-based interpretation of measured equilibrium conductivity and conductivity relaxation is developed to establish thermodynamic, transport, and kinetics parameters for multiple charged defect conducting (MCDC) ceramic materials. The present study focuses on 10% yttrium-doped barium zirconate (BZY10). In principle, using the Nernst-Einstein relationship, equilibrium conductivity measurements are sufficient to establish thermodynamic and transport properties. However, in practice it is difficult to establish unique sets of properties using equilibrium conductivity alone. Combining equilibrium and conductivity-relaxation measurements serves to significantly improve the quantitative fidelity of the derived material properties. The models are developed using a Nernst-Planck-Poisson (NPP) formulation, which enables the quantitative representation of conductivity relaxations caused by very large changes in oxygen partial pressure.

Ni-Infiltrated Spherical Porcelain Support as Potential Steam Reforming Microchannel Reactor.

This paper describes the fabrication of kaolinite (Al2O3-2SiO2-2H2O) spherical bulbs by slip casting. The bisque-fired parts present a porosity of about 30% with submicron porosity confirmed by scanning electron microscopy. In addition, plate-like grains with channels were observed. After nickel infiltration of the specimens, nanosized Ni particles covered the surfaces of the channels of these grains. Permeation tests in 5% H2 at 400 and 600 °C resulted in fluxes between 0.05 and 0.06 mol·m-2·s-1 at a pressure gradient of 200 MPa·m-1. Potential applications of these specimens include supports for hydrocarbon (namely ethanol) steam reforming.

Slip Casting and Solid-State Reactive Sintering of BCZY(BaCexZr0.9-xY0.1O3-d)-NiO/BCZY Half-Cells.

Slip casting was used to prepare BaCexZr0.9-xY0.1O3-d(BCZY)-NiO tubes with a diameter of ½ inches (1.25 cm) and ¾ inches (1.875 cm). Two compositions were studied: BCZY18 and BCZY27 for x = 0.1 and 0.2, respectively. The unfired tubes were then dip-coated with three layers of the BCZY electrolyte membrane. Solid-state reactive sintering was used, meaning that the support and membrane were prepared with the precursors (oxides and carbonates). After co-sintering at 1550 °C, a 20-micron thick dense BCZY layer was well-adhered to the 1 mm thick BCZY-NiO support, as confirmed by scanning electron microscopy. The sintered BCZY-NiO/BCZY tubes were sealed onto alumina or BCZY substrates using a silver-based braze (with TiO2 and CuO additions). Gas tightness was achieved under 2 bar when covering the silver braze with a ceramic (Resbond) sealing layer. These slip cast tubes are intended for use as hydrogen electrodes in various protonic ceramic devices, and the advantages of short tubes for reactor design are discussed.

Modeling Electro-Chemo-Mechanical Behaviors within the Dense BaZr0.8Y0.2O3-δ Protonic-Ceramic Membrane in a Long Tubular Electrochemical Cell.

This paper reports an extended Nernst-Planck computational model that couples charged-defect transport and stress in tubular electrochemical cell with a ceramic proton-conducting membrane. The model is particularly concerned with coupled chemo-mechanical behaviors, including how electrochemical phenomena affect internal stresses and vice versa. The computational model predicts transient and steady-state defect concentrations, fluxes, stresses within a thin BaZr0.8Y0.2O3-δ (BZY20) membrane. Depending on the polarization (i.e., imposed current density), the model predicts performance as a fuel cell or an electrolyzer. A sensitivity analysis reveals the importance of thermodynamic and transport properties, which are often not readily available.

Channelized Substrates Made from BaZr0.75Ce0.05Y0.2O3-d Proton-Conducting Ceramic Polymer Clay.

A novel process for producing thick protonic ceramics for use in hydrogen separation membrane reactors is demonstrated. Polymer clay bodies based on polyvinyl acetate (PVA) and mineral oil were formulated, and they permitted parts with complex architectures to be prepared by simple, low-pressure molding in the unfired, "green" state. Ceramic proton conductors based on doped barium zirconate/cerate, made by solid-state reactive sintering, are particularly well-suited for the polymer clay process. In this work, the ceramic proton conductor, BZCY755 (BaZr0.75Ce0.05Y0.2O3-d) was fabricated into a variety of shapes and sizes. Test coupons were produced to confirm that the polymer clay route leads to a high-quality ceramic material suitable for the demanding environment of high-temperature membrane reactors. It has been demonstrated that protonic ceramic specimens with the requisite properties are easily prepared at the laboratory scale. The polymer clay fabrication route opens up the possibility of high-volume, low-cost manufacturing at a commercial scale, by a process similar to how dinnerware and sanitary porcelain are produced today.

Thermodynamic Insights for Electrochemical Hydrogen Compression with Proton-Conducting Membranes.

Membrane electrode assemblies (MEA) based on proton-conducting electrolyte membranes offer opportunities for the electrochemical compression of hydrogen. Mechanical hydrogen compression, which is more-mature technology, can suffer from low reliability, noise, and maintenance costs. Proton-conducting electrolyte membranes may be polymers (e.g., Nafion) or protonic-ceramics (e.g., yttrium-doped barium zirconates). Using a thermodynamics-based analysis, the paper explores technology implications for these two membrane types. The operating temperature has a dominant influence on the technology, with polymers needing low-temperature and protonic-ceramics needing elevated temperatures. Polymer membranes usually require pure hydrogen feed streams, but can compress H 2 efficiently. Reactors based on protonic-ceramics can effectively integrate steam reforming, hydrogen separation, and electrochemical compression. However, because of the high temperature (e.g., 600 ° C) needed to enable viable proton conductivity, the efficiency of protonic-ceramic compression is significantly lower than that of polymer-membrane compression. The thermodynamics analysis suggests significant benefits associated with systems that combine protonic-ceramic reactors to reform fuels and deliver lightly compressed H 2 (e.g., 5 bar) to an electrochemical compressor using a polymer electrolyte to compress to very high pressure.

Assessing Substitution Effects on Surface Chemistry by in Situ Ambient Pressure X-ray Photoelectron Spectroscopy on Perovskite Thin Films, BaCe xZr0.9- xY0.1O2.95 ( x = 0; 0.2; 0.9).

Performance of proton-solid oxide fuel cells (H+-SOFC) is governed by ion transport through solid/gas interfaces. Major breakthroughs are then intrinsically linked to a detailed understanding of how parameters tailoring bulk proton conductivity affect surface chemistry in situ, at an early stage. In this work, we studied proton and oxygen transport at the interface between H+-SOFC electrolyte BaCe xZr0.9- xY0.1O2.95 ( x = 0; 0.2; 0.9) thin films and the gas (100 mTorr of H2O and O2) by using synchrotron-based ambient pressure X-ray photoelectron spectroscopy at operating temperature (>400 °C). We developed highly textured BaCe xZr0.9- xY0.1O2.95 epitaxial thin films, which exhibit high level of in-plane proton conductivity, that is, up to 0.08 S cm-1 at 500 °C for x = 0.9. Upon applying 100 mTorr water partial pressure above 300 °C, major changes are observed only in the O 1s and Y 3d core level spectra, with a clear Zr/Ce ratio dependency. OH- formation is favored by Ce content while initiated near Y. Hydration is also associated with surface secondary phase growth comprising oxygen-under-coordinated yttrium and/or yttrium hydroxide. With BaCe0.2Zr0.7Y0.1O2.95, high levels of ionic conductivities and chemical stability are obtained as a result of the optimized surface reaction kinetics, with low activation energy barrier for proton transport while restraining formation of OH-/SO42- adsorb species.

Effect of Cation Ordering on the Performance and Chemical Stability of Layered Double Perovskite Cathodes.

The effect of A-site cation ordering on the cathode performance and chemical stability of A-site cation ordered LaBaCo2O5+δ and disordered La0.5Ba0.5CoO3-δ materials are reported. Symmetric half-cells with a proton-conducting BaZr0.9Y0.1O3-δ electrolyte were prepared by ceramic processing, and good chemical compatibility of the materials was demonstrated. Both A-site ordered LaBaCo2O5+δ and A-site disordered La0.5Ba0.5CoO3-δ yield excellent cathode performance with Area Specific Resistances as low as 7.4 and 11.5 Ω·cm² at 400 °C and 0.16 and 0.32 Ω·cm² at 600 °C in 3% humidified synthetic air respectively. The oxygen vacancy concentration, electrical conductivity, basicity of cations and crystal structure were evaluated to rationalize the electrochemical performance of the two materials. The combination of high-basicity elements and high electrical conductivity as well as sufficient oxygen vacancy concentration explains the excellent performance of both LaBaCo2O5+δ and La0.5Ba0.5CoO3-δ materials at high temperatures. At lower temperatures, oxygen-deficiency in both materials is greatly reduced, leading to decreased performance despite the high basicity and electrical conductivity. A-site cation ordering leads to a higher oxygen vacancy concentration, which explains the better performance of LaBaCo2O5+δ. Finally, the more pronounced oxygen deficiency of the cation ordered polymorph and the lower chemical stability at reducing conditions were confirmed by coulometric titration.

Readily processed protonic ceramic fuel cells with high performance at low temperatures.

Because of the generally lower activation energy associated with proton conduction in oxides compared to oxygen ion conduction, protonic ceramic fuel cells (PCFCs) should be able to operate at lower temperatures than solid oxide fuel cells (250° to 550°C versus ≥600°C) on hydrogen and hydrocarbon fuels if fabrication challenges and suitable cathodes can be developed. We fabricated the complete sandwich structure of PCFCs directly from raw precursor oxides with only one moderate-temperature processing step through the use of sintering agents such as copper oxide. We also developed a proton-, oxygen-ion-, and electron-hole-conducting PCFC-compatible cathode material, BaCo(0.4)Fe(0.4)Zr(0.1)Y(0.1)O(3-δ) (BCFZY0.1), that greatly improved oxygen reduction reaction kinetics at intermediate to low temperatures. We demonstrated high performance from five different types of PCFC button cells without degradation after 1400 hours. Power densities as high as 455 milliwatts per square centimeter at 500°C on H2 and 142 milliwatts per square centimeter on CH4 were achieved, and operation was possible even at 350°C.