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All sourcesNASA NTRSDOE OSTI
DOE OSTI2018

Highly Selective and Stable Multivariable Gas Sensors for Enhanced Robustness and Reliability of SOFC Operation

GE Global Research, in partnership with SUNY Polytechnic Institute (SUNY Poly) and GE–Fuel Cells LLC, designed, built, and tested multi-gas sensor prototypes for in situ monitoring of gases produced during steam reforming in solid oxide fuel cell (SOFC) systems. To be widely adopted and to deliver a lower operating cost for customers, SOFC systems should enhance their operation reliability and improve stack robustness. These needs can be achieved by early diagnostics of potential upsets by using in-situ gas sensors for the real-time monitoring of gas mixture compositions. Thus, this project objective was to achieve selectivity and stability of sensing of gases for SOFC applications by implementing a new generation of gas sensors, known as multivariable sensors. Such sensors are intended to complement the mature traditional analytical instruments based on sensor performance and design characteristics. The key sensor-performance characteristics include accurate detection and quantitation of several gases in their mixtures and stability of operation in unattended applications. The key design characteristics of sensors include their unobtrusive form factor and cost-effectiveness. The duration of the project was 18 months with the project structure that included three technical tasks such as (1) design and laboratory validation of multivariable sensors for selective detection of H 2 and CO gases, (2) laboratory validation of sensor stability over a two-week testing, and (3) field-validation of the developed multivariable sensor system prototype at GE–Fuel Cells factory. Multi-gas detection was achieved with multivariable photonic sensors designed to operate at elevated temperature. The sensor design was based on three-dimensional (3D) bio-inspired photonic nanostructure that was fabricated using materials responsive to gases of interest such as H 2 and CO. The gas discrimination and the rejection of interferences such as CH 4 , H 2 O, and others was performed by optimizing the design parameters of the 3D photonic nanostructures such as their composition and morphology. Planar sol-gel and sputtered sensing films were fabricated as controls. As a result of the fabrication, functionalization, excitation, and performance testing of 3D photonic sensors, we developed initial design rules for high temperature multivariable sensors. These design rules pave the way for the new generation of cost-effective industrial sensors. Stability of sensor operation was tested in the laboratory conditions under variations of the ambient environments. Stability tests were designed in the order of enhanced complexity and realism of sensor operation and included quantitation of a single gas, quantitation of a single gas in the presence of interferences, and quantitation of two and three gases. We have found that conventional machine learning data analysis stools were unable to correct for the sensor drift. Thus, we have developed new methods of machine learning data analysis that provided us with needed performance stability. Such performance improvement in gas sensing was a significant milestone in bringing our multivariable sensors to practical applications. The project culminated with initial field validation of developed multivariable sensor prototypes at GE–Fuel Cells LLC. The in situ data generated by the sensor system in the lab and field conditions provided inputs that advanced our fundamental understanding of gas sensing at high temperatures to enable sensors for SOFC applications and allowed development of the recommendations for further deliverables.

47 OTHER INSTRUMENTATION↗
DOE OSTI2021

Performance of a Natural Gas Solid Oxide Fuel Cell System With and Without Carbon Capture

The fuel cell program at the United States Department of Energy (DOE) National Energy Technology Laboratory (NETL) is focused on the development of low-cost, highly efficient, and reliable fossil-fuel-based solid oxide fuel cell (SOFC) power systems that can generate environmentally-friendly electric power with at least 90 percent carbon capture. NETL’s SOFC technology development roadmap is aligned with near-term market opportunities in the distributed generation sector to validate and advance the technology while paving the way for utility-scale natural gas (NG)- and coal-derived synthesis gas-fueled applications via progressively larger system demonstrations. The present study represents a part of a series of system evaluations being carried out at NETL to aid in prioritizing technological advances along research pathways to the realization of utility-scale SOFC systems, a transformational goal of the fuel cell program. In particular, the system performance of utility-scale NG fuel cell (NGFC) systems with and without carbon dioxide (CO2) capture is presented. The NGFC system analyzed features an external auto-thermal reformer (ATR) feeding the fuel to the SOFC system consisting of planar anode-supported SOFC with separated anode and cathode off-gas streams. In systems with CO2 capture, an air separation unit (ASU) is used to provide the oxygen for the ATR and for the combustion of unutilized fuel in the SOFC anode exhaust along with a CO2 purification unit to provide a nearly pure CO2 stream suitable for transport for usage in enhanced oil recovery operations or for storage in underground saline formations. Remaining thermal energy in the exhaust gases is recovered in a bottoming steam Rankine cycle while supplying any process heat requirements. A reduced order model (ROM) developed at the Pacific Northwest National Laboratory (PNNL) is used to predict the SOFC performance. The ROM, while being computationally effective for system studies, provides other detailed information about the state of the stack, such as the internal temperature gradient, generally not available from simple performance models often used to represent the SOFC. Such additional information can be important in system optimization studies to preclude operation under off-design conditions that can adversely impact overall system reliability. The NGFC system performance was analyzed by varying salient system parameters, including the percent of internal (to the SOFC module) NG reformation—ranging from 0 to 100 percent—fuel utilization, and current density. The impact of advances in underlying SOFC technology on electrical performance was also explored.

solid oxide fuel cell (SOFC), natural gas fuel cel↗
DOE OSTI2024

Cell and Stack Degradation Evaluation and Modeling

Presentation on NETL's solid oxide fuel cell (SOFC) work plan research (FWP 1022411) given by invitation to the 2024 Hydrogen Program Annual Merit Review meeting in Arlington, VA on May 7, 2024.

Abernathy, Harry↗
DOE OSTI2026

Automation of Solid Oxyde Electrolyzer Cell (SOEC) & Stack Assembly

The work performed under this agreement before the No/Go decision amounted to the following: 1. Preliminary manufacturing requirements defined by business sensitivity, baseline processes & risk assessment; 2. Process & materials development, in-line gauge exploration, and preliminary automation work used to reduce risk & further refine equipment specifications; 3. “Request for Quote” issued to multiple suppliers for major equipment; 4. Application specific equipment, hardware, and fixturing will be more beneficial to fabricate inhouse; 5.Current proposals & estimates meet cycle time, capital spend, & direct labor; space is on target but requires awareness; 6. Team will continue to explore opportunities to reduce risk (dry time, traceability); 7. Go / No-Go, Purchase Orders, Equipment build & commissioning next All other future task were not completed because during the Go /No-Go decision it was confirmed this project was a "No-Go" and did not proceed past BP1; these included the following: 1. Preliminary manufacturing requirements defined by business sensitivity, baseline processes & risk assessment; 2. Process & materials development, in-line gauge exploration, and preliminary automation work used to reduce risk & further refine equipment specifications; 3. “Request for Quote” issued to multiple suppliers for major equipment; 4. Application specific equipment, hardware, and fixturing will be more beneficial to fabricate inhouse; 5. Current proposals & estimates meet cycle time, capital spend, & direct labor; space is on target but requires awareness; 6. Team will continue to explore opportunities to reduce risk (dry time, traceability) In final preparation of the termination of the Automation of Solid Oxyde Electrolyzer Cell (SOEC) & Stack Assembly, Cummins has purchased no equipment with government funds, and there is no government-owned property in Cummins possession related to this project. Minimal labor and travel were completed and paid. This acts as the Final technical report and concludes our business with DOE on this grant.

36 MATERIALS SCIENCE↗
DOE OSTI2021

High performance protonic ceramic fuel cell systems for distributed power generation

The technology landscape around distributed generation continues to evolve in response to increasing demand for high-efficiency, low-emission, low-cost power generation. While emerging distributed power technologies, such as solid oxide fuel cells (SOFCs), continue to advance, they still face challenges due to their high capital costs, and shorter lifetimes that typically arise from electrochemical stack performance degradation at high operating temperatures (>750 °C). Recent advancements in protonic ceramic fuel cells (PCFCs) offer the potential to mitigate drawbacks of their higher temperature SOFC counterparts by enabling lower operating temperatures (550 °C–600 °C) with acceptable power densities. Here the present work leverages the recent progress in protonic ceramic cell and stack technology development to generate viable system configurations and evaluate the energetic performance potential of PCFC-based systems for stationary power generation. Process system engineering of two water-neutral system concepts, which provide 25 kW of electric power and process hot water, are presented and evaluated through sensitivity studies. Stack design parameters are altered and used to gauge the effect on system performance characteristics, including fuel cell stack and balance-of-plant sizing requirements, and electric and cogeneration efficiencies. The study finds that the potentially high per-pass fuel utilization capability of PCFC stacks could enable unprecedented electric efficiencies approaching 70% without hybridization with other prime movers.

25 ENERGY STORAGE↗
DOE OSTI2019

Roll-to-Roll SOFC Manufacturing for Low Cost Energy Generation

Oak Ridge National Laboratory (ORNL) and Redox Power Systems, LLC. collaborated on this project to develop an integrated, continuous roll-to-toll (R2R) manufacturing processes to produce solid oxide fuel cells (SOFCs). SOFCs are ceramic-based electrochemical devices that efficiently produce electricity from hydrogen-containing fuels, including natural gas. Standard processes for manufacturing SOFCs include tape casting of the anode and electrolyte, followed by stacking of the layers, and lamination using a uniaxial press or isostatic press. After high temperature firing, the cathode and electrical contact are screen printed and fired once again to complete the cell. This effort aimed to further develop R2R tape fabrication processes for green cell fabrication with the DOE Battery Manufacturing Facility (BMF) at ORNL as next generation improvements to current methods, focusing on R2R calendering and slot die coating for lower cost, high volume approaches for multilayer green cell fabrication. Two paths were investigated in parallel in this project. The first path was to optimize R2R processing using traditional tape cast materials from the Redox production chain on the BMF’s heated calender for compressing and laminating multilayer materials. The second path was to use BMF’s pilot-scale slot-die coater for R2R manufacturing as an alternative to tape casting of some or all of the layers in the green cell. Processes have been developed and and process conditions have been identified. Additionally, basic process economics were estimated for comparison to Redox current manufacturing approaches for the applicable process modules. The SBV program results will enable Redox to advance lower cost R2R manufacturing processes to produce millions of green cells per year on a single production line. As a result of this work, one invention disclosure has been submitted. In addition, one paper is under preparation for submission to a peer-reviewed journal.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2024

Improving Cost and Efficiency of the Scalable Solid Oxide Fuel Cells Power System

The objective of this project was to design and develop a 20kW range small-scale solid oxide fuel cells (SOFC) power system for applications such as data centers and commercial buildings. The original plan included a 5,000 hours demonstration and a Techno-Economic Analysis (TEA) which were dropped as part of project termination. The original project plan was to use a stack with a cross-flow cell design which had previously been tested for 500 hours at a community college in Malta, NY. However, it was decided to move to the advanced R-SOFC co-flow cell developed under Department of Energy Award DE-FE0031971. The advanced cell design has the advantage of a larger active area for the same manufacturing footprint which results in fewer required cells for the same stack power, hence a higher volumetric power density (kW/L) and lower cost per kW than the original cross-flow cell design. A full SOFC system Simulink model was developed and calibrated with testing data from a fuel cell stack and BOP (balance of plant) components. The simulation results from the calibrated model showed an acceptable match with the experimental data. A structural analysis conducted for various load scenarios indicated no high stress areas for all spatial directions. Major electrical system components were acquired, built and successfully tested. System sensors were verified and validated against controls. Safety checks, a diagnostic check, PID tuning, and control software commissioning tasks were also conducted. The power electronics prototype was delivered and trial testing completed. Balance of Plant component testing and simulation work was conducted to characterize Reformer-Heat Exchanger heat transfer and backpressure and reformer catalyst methane conversion and product selectivity. Simulations were conducted to design the Anode and Cathode fluid passages and size the air-air and fuel-fuel heat exchangers. A Burner operation map was created from test data and the Anode Gas Recirculation blower was tested to evaluate its durability. The SOFC system used a horizontal style design where components sit directly on a casting with a direct connection to the skid. This design has efficient packaging and a small footprint with approximate dimensions of 750 mm x 700 mm x 1700 mm. An SOFC system was built and successfully tested at the Malta, NY facility The system for over 500 hours under load of which over 300 hours was at full load of 20 kW.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2022

Laser 3D printing of highly compacted protonic ceramic electrolyzer stack

Solid oxide electrolysis cells (SOECs) for H 2 production is a core technology for H2@scale. However, its conventional manufacturing methods adapted from the manufacture of solid oxide fuel cells (SOFC) need high cost, especially for small-volume production. The emerging laser 3D printing (L3DP) technology with computer-aided 3D printing and computer-controlled laser processing can fulfill layer-by-layer digital shaping and rapid in-situ consolidating feedstock into complicated geometries. L3DP, a promising additive manufacturing (AM) technology, has achieved significant success in manufacturing plastic and metal parts, which is currently attracting considerable attention for the cost-effective, rapid, and flexible manufacturing of heterogeneous multilayered ceramic devices (e.g., SOECs, SOFCs, and solid-state batteries). It is believed that the L3DP can integrate the advantages of selective consolidation of heterogeneous layers, accurate control of layer microstructures, high processing heat efficiency, high processing speed, high stack compactness, high stack design flexibility, and low stack sealing area for cost-effective, rapid, and flexible manufacturing of SOECs to meet DOE’s electrolyzer target.

08 HYDROGEN↗
DOE OSTI2018

Abstract - Cooperative Research and Development Agreement between Atrex Energy, Inc. and National Energy Technology Laboratory

The National Energy Technology Laboratory (NETL) will collaborate with Atrex Energy through CRADA (AGMT-0680) to demonstrate their patent-pending, single step electrode infiltration technique on Atrex commercial-scale tubular solid oxide fuel cells (SOFC). For SOFC to be widely accepted in the commercial domain, the stability of the cells must improve and performance degradation must be mitigated for the technology to be economically viable. NETL’s single-step electrode infiltration technique addresses these challenges by introducing a highly-active nanocatalyst material into the SOFC microstructure, improving cell performance and longevity. Atrex will use NETL’s technology to generate two stacks of cells to effectively demonstrate the benefits at a commercially-relevant scale. Upon detailed analysis of the first stack test results, NETL will optimize the solution chemistry of the nanocatalyst material for an improved formula to incorporate into the second test. This work is funded through a Technology Commercialization Fund that has been awarded to NETL and Atrex as is expected to result in licensing of the technology upon a successful project.

25 ENERGY STORAGE↗
DOE OSTI2019

DE-FE0026098 Final Report - Advanced Materials and Manufacturing Processes for SOFC Power Systems Revision 1

The aim of the project is to qualify an integrated material set and processing solution for selected metallic components of an advanced integrated stack block. As the integrated stack block is the “engine” of the solid oxide fuel cell power system, the project will also support significant cost reductions, increased reliability, and improved performance of the LG Fuel Cell Systems Inc. (“LGFCS”) cell and stack technology to be included in the initial commercial product offering. In the proposed work an integrated material set, and processing solution will be developed using powder metals processing which has been proven to be an enabling technology capable of delivering net or near net shape components, as well as for creating compositions, microstructures, and properties that are otherwise unattainable. Several advanced manufacturing processes will be screened to select one or more that are most advantageous for the selected metallic components when produced at commercial volumes. This work will be accomplished through the integration of metallurgists and processing engineers from Carpenter Technology, with the product design and cost engineers from LGFCS. The expected outcome of the proposed work is an optimized material set and processing solution that will reduce the current cost.

03 NATURAL GAS↗
DOE OSTI2018

Cost-effective Manufacturing and Morphological Stabilization of Nanostructured Cathodes for Commercial SOFCs

The overall goals of the program were to develop methods for preparing and stabilizing SOFC electrodes by infiltration that can be manufactured on a practical scale, then transfer those methods to cells in stacks. Cathodes prepared by infiltration of nanoparticles into a porous scaffold of the electrolyte have demonstrated outstanding electrochemical performance and mechanical strength but are difficult to manufacture due to the large number of infiltration steps required to produce a conductive composite and show poor stability due to sintering of the nanoparticles. At Penn, the main goal was to develop a fabrication method that uses only a small number of infiltration steps. Infiltration with molten salts and electrodeposition were pursued but deemed impractical. A method in which an electronically conductive scaffold consisted of a composite of a mixed conductor, LSF (La 0.9 Sr 0.1 FeO 3 ), with yttria-stabilized zirconia (YSZ) was found to be promising. While some cation mixing between LSF and YSZ was observed during calcination, there was no evidence for new phases in XRD and incorporation of Zr into the perovskite could be minimized by reducing the Sr content of the LSF. To stabilize nanoparticles infiltrated into the LSF-YSZ composite scaffold, the USC team examined the effects of Atomic Layer Deposition with ZrO 2 and infiltrated nanoparticles. Significantly enhanced stability was observed with the infiltrated nanoparticles. The FuelCell Energy team prepared 4”x4” cells in which an LSF-YSZ composite scaffold was cofired with the YSZ electrolyte and infiltrated with LSCF nanoparticles. Apparently because the LSF-YSZ scaffold layer was very thin in this case, the cation mixing that occurred during calcination resulted in a poor scaffold-electrolyte interface which caused reduced performance.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Cost-effective Manufacturing and Morphological Stabilization of Nanostructured Cathodes for Commercial Solid Oxide Fuel Cells (SOFCs) [Slides]

The overall goals of the program were to develop methods for preparing and stabilizing SOFC electrodes by infiltration that can be manufactured on a practical scale, then transfer those methods to cells in stacks. Cathodes prepared by infiltration of nanoparticles into a porous scaffold of the electrolyte have demonstrated outstanding electrochemical performance and mechanical strength but are difficult to manufacture due to the large number of infiltration steps required to produce a conductive composite and show poor stability due to sintering of the nanoparticles. At Penn, the main goal was to develop a fabrication method that uses only a small number of infiltration steps. Infiltration with molten salts and electrodeposition were pursued but deemed impractical. A method in which an electronically conductive scaffold consisted of a composite of a mixed conductor, LSF (La 0.9 Sr 0.1 FeO 3 ), with yttria-stabilized zirconia (YSZ) was found to be promising. While some cation mixing between LSF and YSZ was observed during calcination, there was no evidence for new phases in XRD and incorporation of Zr into the perovskite could be minimized by reducing the Sr content of the LSF. To stabilize nanoparticles infiltrated into the LSF-YSZ composite scaffold, the USC team examined the effects of Atomic Layer Deposition with ZrO 2 and infiltrated nanoparticles. Significantly enhanced stability was observed with the infiltrated nanoparticles. The FuelCell Energy team prepared 4”x4” cells in which an LSF-YSZ composite scaffold was cofired with the YSZ electrolyte and infiltrated with LSCF nanoparticles. Apparently because the LSF-YSZ scaffold layer was very thin in this case, the cation mixing that occurred during calcination resulted in a poor scaffold-electrolyte interface which caused reduced performance.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2025

Developing Stable Critical Materials and Microstructure for High-Flux and Efficient Hydrogen Production through Reversible Solid Oxide Cells

Reversible Solid Oxide Cells (RSOCs), which operate as either Solid Oxide Fuel Cells (SOFCs) or Solid Oxide Electrolytic Cells (SOECs), hold great promise for clean, high-efficiency energy conversion and hydrogen production. However, their commercial potential is hindered by stability issues arising from temperature-induced materials degradation. While substantial progress has been made in developing durable, reduced-temperature SOFCs - bringing them closer to commercial deployment, SOECs still exhibit substantially higher degradation rates at both the cell and stack levels under practical operating conditions.

08 HYDROGEN↗
DOE OSTI2019

DE-FE0031180 Final Report - LGFCS Prototype System Testing - R0

In the project, LGFCS assembled and tested its modular SOFC Power System that incorporates all critical technology improvements identified for its “product-like” demonstration. This product demonstrator is expected to meet customer and LGFCS performance expectations for operation, availability, durability and serviceability. The principal technology improvements are aimed at increasing the fuel cell power output and reducing the stack degradation rate. Improvements were also made for added system robustness and increased reliability. The objective of this program is to test a 250kWe thermally self-sustaining modular solid oxide fuel cell (SOFC) Power System for a minimum of 5,000 hours while advancing this commercial prototype product demonstrator to a Technical Readiness Level (TRL) 7. The SOFC system was tested on a site provided by Stark State College in North Canton, Ohio. System performance and degradation as well as cost estimates were compared to established SOFC Program performance metrics to assess progress. The major achievements were to assemble, and QA qualify 70 fuel cell strips for 12 integrated blocks into a fuel cell vessel and install it into a generator module with the fuel and power electronics modules on the test site. Performance to date included over 1800 hours on load at 250 KW-AC to the grid with a DC efficiency of 61% and AC efficiency of 55%. Power degradation was less than 0.4% per 1000 hours and NOx emissions met standards. The LGFCS SOFC Prototype System (GEN0) was demonstrated in an operational environment and therefore achieving Technical Readiness Level 7. The work presented here represents the efforts of all the employees of LG Fuel Cell Systems. Their dedication and hard work made GEN0 possible and successful.

03 NATURAL GAS↗
DOE OSTI2019

LGFCS Prototype System Testing (Final Report)

In the project, LGFCS assembled and tested its modular SOFC Power System that incorporates all critical technology improvements identified for its “product-like” demonstration. This product demonstrator is expected to meet customer and LGFCS performance expectations for operation, availability, durability and serviceability. The principal technology improvements are aimed at increasing the fuel cell power output and reducing the stack degradation rate. Improvements were also made for added system robustness and increased reliability. The objective of this program is to test a 250kWe thermally self-sustaining modular solid oxide fuel cell (SOFC) Power System for a minimum of 5,000 hours while advancing this commercial prototype product demonstrator to a Technical Readiness Level (TRL) 7. The SOFC system was tested on a site provided by Stark State College in North Canton, Ohio. System performance and degradation as well as cost estimates were compared to established SOFC Program performance metrics to assess progress. The major achievements were to assemble, and QA qualify 70 fuel cell strips for 12 integrated blocks into a fuel cell vessel and install it into a generator module with the fuel and power electronics modules on the test site. Performance to date included over 1800 hours on load at 250 KWAC to the grid with a DC efficiency of 61% and AC efficiency of 55%. Power degradation was less than 0.4% per 1000 hours and NOx emissions met standards. The LGFCS SOFC Prototype System (GEN0) was demonstrated in an operational environment and therefore achieving Technical Readiness Level 7. The work presented here represents the efforts of all the employees of LG Fuel Cell Systems. Their dedication and hard work made GEN0 possible and successful.

03 NATURAL GAS↗
DOE OSTI2018

Sol-gel synthesis of Mn1.5Co1.5O4 spinel nano powders for coating applications

Highlights: • Nano powder of Mn/Co spinel, applicable to solid oxide fuel cell, is synthesized. • The sol-gel synthesis of nanocrystalline Mn{sub 1.5}Co{sub 1.5}O{sub 4} spinel is investigated. • Sol-gel annealing temperature, time, and metal-to-citrate ratio are evaluated. • The optimum conditions for producing dual phase of Mn{sub 1.5}Co{sub 1.5}O{sub 4} are achieved. - Abstract: Mn{sub 1.5}Co{sub 1.5}O{sub 4} oxide spinels are widely used as protective coatings for stainless steel interconnects within planar solid oxide fuel cell stacks. Containing both cubic and tetragonal crystalline phases, these Mn/Co oxide spinels exhibit favorable thermal stability and electronic conductivity for the SOFC interconnect application. Slurry-based coating applications of Mn/Co oxides require precursor powders, which can benefit from being nano-structured. In this study, the sol-gel synthesis of nanocrystalline Mn{sub 1.5}Co{sub 1.5}O{sub 4} spinel is investigated. The decomposition of sol-gel precursors, as well as the crystalline phase structures and microstructures of the product Mn{sub 1.5}Co{sub 1.5}O{sub 4} are characterized by differential thermal and thermogravimetric (DTA/TG) analysis, X-ray diffraction (XRD), and transmission electron microscopy (TEM). The effects of various sol-gel annealing temperatures (T), treatment times (t), and citrate-to-metal ratios (Rc) are evaluated. Results suggest that nanocrystalline Mn{sub 1.5}Co{sub 1.5}O{sub 4} spinel can be synthesized around 1050 °C, and that T = 1050 °C, t = 6 h and Rc = 2 are optimum conditions for producing the smallest grain size. Image analysis of TEM results shows that the size of Mn{sub 1.5}Co{sub 1.5}O{sub 4} crystallites increases with increasing temperature, with average particle sizes ranging from ∼70 nm to ∼1 μm. Selected area diffraction pattern (SADP) of Mn{sub 1.5}Co{sub 1.5}O{sub 4} spinel synthesized at 800 °C confirms the dual (cubic/tetragonal) structure of Mn{sub 1.5}Co{sub 1.5}O{sub 4}.

77 NANOSCIENCE AND NANOTECHNOLOGY↗
DOE OSTI2024

Development of Stable Solid Oxide Electrolysis Cells for Low-Cost Hydrogen Production

The project objective was to demonstrate a solid oxide cell-based steam electrolysis stack that exhibits robustness, reliability, endurance, hydrogen purity, and produces hydrogen at elevated pressure of 2 to 3 bar. Innovative materials and processing methods were evaluated to improve degradation characteristics. Performance improvement focused on nearly all layers involved in the cell and stack assembly. Primary attention was paid to zirconia-ceria interface resistance control via sintering optimization and decrease in degradation from the oxygen electrode by evaluating low strontium (Sr) or Sr-free composition for both the oxygen electrode and current collection layer. Stack robustness was addressed by validating redox tolerance of fuel electrode, confirming capability of cells to survive repeated thermal cycles, studying the effect of pressure on performance and degradation, evaluating the effect of contamination on fuel and oxygen electrode performance and degradation, and identifying mitigation strategies to improve performance. The characterization included evaluation of electrochemical performance and stability followed by microstructural analysis. At the cell level, performance and stability improvements were achieved by incorporating a Sr-free oxygen electrode and a denser oxygen electrode barrier layer. At the stack level, pressurized operation reduces demand on first stage compression, the redox tolerant fuel electrode mitigates risk from service interruptions, and improvements to interconnect coating alleviate chromium (Cr) contamination effects. The denser barrier layer was achieved by adding a sintering aid to the samaria-doped ceria (SDC) composition that reduced sintering temperature by 150 °C. The resulting density was on par with the baseline SDC barrier layer density and the lower sintering temperature resulted in less resistive phase formation during sintering. Button cell tests did not demonstrate a change in performance when exposed to silicon (Si) or manganese (Mn) impurities to the fuel electrode and Cr impurity to the oxygen electrode. More detailed study however is warranted. The project addressed SOEC performance and stability at the cell and stack levels through a systematic approach to known sources of degradation that were combined and tested in three stack tests using an electrolyte supported cell design to allow for evaluation of a variety of fuel and oxygen electrode compositions. STK-82 and STK-83 had identical compositions. STK-100 incorporated the best materials and processing variables developed under this and concurrent projects, and was tested at elevated pressure in steam electrolysis. • STK-82 recovered performance after redox and thermal cycling, demonstrating the robustness of the stack and seals. It exhibited stable performance in testing for 500 hours in SOEC mode, followed by 300 hours of cycling between SOEC and SOFC tests. Degradation during SOEC operation was 1.8 %/ 1,000 hours. • STK-83 generated hydrogen at >80% steam conversion, and oxygen above 98.5 % purity during pressurized operation. Both hydrogen and oxygen were generated at 3 barg pressure without the use of a pressure vessel. In addition to balanced pressure, electrolysis operation at 1 bar differential pressure across anode and cathode was also demonstrated to substantial the robustness of the cell and seal. • STK-100 measured at initial ambient pressure conditions showed an area specific resistance of 1.1 ohm-cm 2 , and STK-83 had 1.3 ohm-cm 2 .

08 HYDROGEN↗
DOE OSTI2022

Cooperative Research and Development Agreement between National Energy Technology Laboratory and OxEon Energy LLC (Abstract)

The National Energy Technology Laboratory (NETL) will collaborate with OxEon Energy LLC (OxEon) to apply NETL’s patented single step electrode infiltration technique on OxEon solid oxide fuel cells (SOFC) for Electric Vertical Takeoff and Landing (eVTOL) aircraft applications below one megawatt. The expanded application of the OxEon solid oxide cell technology on eVTOL aircraft seeks to demonstrate a high performance, durable SOFC system that will produce more electricity per weight based on possible operation on ammonia as fuel. NETL’s single-step electrode infiltration technique addresses these challenges by introducing a highly active nanocatalyst material into the SOFC electrode microstructure to improving cell performance, longevity, and fuel flexibility. Specifically for this project, OxEon will incorporate NETL’s technology to generate a small stack of cells (1 kW output) to demonstrate a fuel flexible system at a relevant scale. NETL will apply its infiltration technology to cells supplied by OxEon, test the effectiveness of the infiltration internally at NETL based on performance in hydrogen, and then supply infiltrated cells to OxEon and Pacific Northwest National Laboratory for independent confirmation and for the 1 kW stack test.

30 DIRECT ENERGY CONVERSION↗