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DOE OSTI · 2559004

Sintering protonic zirconate cells with enhanced electrolysis stability and Faradaic efficiency

Tang, Wei [Idaho National Laboratory (INL), Idaho Falls, ID (United States); New Mexico State University, Las Cruces, NM (United States)]·Bian, Wenjuan [Idaho National Laboratory (INL), Idaho Falls, ID (United States)]·Ding, Hanping [Idaho National Laboratory (INL), Idaho Falls, ID (United States); University of Oklahoma, Norman, OK (United States)] (ORCID:0000000287347933)·Ding, Yong [Georgia Institute of Technology, Atlanta, GA (United States)]·Zhao, Zeyu [Idaho National Laboratory (INL), Idaho Falls, ID (United States)] (ORCID:000000018649925X)·Sun, Quanwen [New Mexico State University, Las Cruces, NM (United States)]·Koomson, Samuel [Idaho National Laboratory (INL), Idaho Falls, ID (United States)] (ORCID:0000000238096373)·Wang, You [University of New Mexico, Albuquerque, NM (United States)]·Xu, Boshen [George Mason University, Fairfax, VA (United States)]·Dong, Pei [George Mason University, Fairfax, VA (United States)]·Chen, Dongchang [University of New Mexico, Albuquerque, NM (United States)]·Gomez, Joshua Y. [Idaho National Laboratory (INL), Idaho Falls, ID (United States)]·Feng, Wuxiang [Idaho National Laboratory (INL), Idaho Falls, ID (United States)]·Wu, Wei [Idaho National Laboratory (INL), Idaho Falls, ID (United States)]·Zhou, Meng [New Mexico State University, Las Cruces, NM (United States)]·Dong, Yanhao [Massachusetts Institute of Technology (MIT), Cambridge, MA (United States)] (ORCID:0000000312241015)·Luo, Hongmei [New Mexico State University, Las Cruces, NM (United States)] (ORCID:000000029546761X)·Li, Ju [Massachusetts Institute of Technology (MIT), Cambridge, MA (United States)] (ORCID:0000000278418058)·Ding, Dong [Idaho National Laboratory (INL), Idaho Falls, ID (United States)] (ORCID:0000000269214504)
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Abstract

The emerging applications of steam electrolysis and electrochemical synthesis at 300–600 °C set stringent requirements on the stability of protonic ceramic cells, which cannot be met by Ce-rich electrolytes. A promising candidate is Ce-free BaZr 0.8 Y 0.2 O 3–δ , but its usage has long been hindered due to the high sintering temperatures required for protonic devices. Here we resolved the issue through a co-sintering process, in which the shrinkage stress of a readily sinterable support layer helps to densify the pure BaZr 0.8 Y 0.2 O 3–δ electrolyte membrane at low temperatures. This approach eliminates Ce and harmful sintering aids in the dense zirconate electrolyte membrane, thereby enhancing the Faradaic efficiency and electrochemical stability, especially under harsh operating conditions. Here, the protonic zirconate cells have exceptional performance and demonstrate stable high-steam pressure electrolysis up to 0.7 atm steam pressure, –2 A cm –2 current density and over 800 h of dynamic operation at 600 °C. Our processing breakthrough enables stabilized protonic cells for demanding applications in future energy infrastructure.

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Tang, Wei [Idaho National Laboratory (INL), Idaho Falls, ID (United States); New Mexico State University, Las Cruces, NM (United States)], Bian, Wenjuan [Idaho National Laboratory (INL), Idaho Falls, ID (United States)], Ding, Hanping [Idaho National Laboratory (INL), Idaho Falls, ID (United States); University of Oklahoma, Norman, OK (United States)] (ORCID:0000000287347933), Ding, Yong [Georgia Institute of Technology, Atlanta, GA (United States)], Zhao, Zeyu [Idaho National Laboratory (INL), Idaho Falls, ID (United States)] (ORCID:000000018649925X), Sun, Quanwen [New Mexico State University, Las Cruces, NM (United States)], Koomson, Samuel [Idaho National Laboratory (INL), Idaho Falls, ID (United States)] (ORCID:0000000238096373), Wang, You [University of New Mexico, Albuquerque, NM (United States)], Xu, Boshen [George Mason University, Fairfax, VA (United States)], Dong, Pei [George Mason University, Fairfax, VA (United States)], Chen, Dongchang [University of New Mexico, Albuquerque, NM (United States)], Gomez, Joshua Y. [Idaho National Laboratory (INL), Idaho Falls, ID (United States)], Feng, Wuxiang [Idaho National Laboratory (INL), Idaho Falls, ID (United States)], Wu, Wei [Idaho National Laboratory (INL), Idaho Falls, ID (United States)], Zhou, Meng [New Mexico State University, Las Cruces, NM (United States)], Dong, Yanhao [Massachusetts Institute of Technology (MIT), Cambridge, MA (United States)] (ORCID:0000000312241015), Luo, Hongmei [New Mexico State University, Las Cruces, NM (United States)] (ORCID:000000029546761X), Li, Ju [Massachusetts Institute of Technology (MIT), Cambridge, MA (United States)] (ORCID:0000000278418058), Ding, Dong [Idaho National Laboratory (INL), Idaho Falls, ID (United States)] (ORCID:0000000269214504). 2025-03-14. Sintering protonic zirconate cells with enhanced electrolysis stability and Faradaic efficiency. https://doi.org/10.1038/s44160-025-00765-z

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