Abstract:
The present invention relates to a solid oxide fuel cell comprising a reformer for supporting the solid oxide fuel cell, an anode, an electrolyte, and a cathode. The reformer includes an electroconductive mixture of active material and a polymeric ceramic material shaped to constitute a slab having an upper surface and a lower surface and grooves along at least one of the upper surface and the lower surface and flat regions along the periphery of the grooved surface.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
       [0001]     This application claims priority of U.S. provisional patent application 60/511,083, the specification of which is hereby incorporated by reference. 
     
    
     BACKGROUND OF THE INVENTION  
       [0002]     1) Field of the Invention  
         [0003]     The invention relates to solid electrolyte fuel cells and, more particularly, to reformer supported solid electrolyte fuel cells.  
         [0004]     2) Description of the Prior Art  
         [0005]     Fuel cells are electrochemical devices that convert chemical energy in fuels (such as hydrogen, methane, butane or even gasoline and diesel) into electrical energy by exploiting the natural tendency of oxygen and hydrogen to react. By controlling the means by which such reaction occurs and directing the reaction through a device, it is possible to harvest the energy given off by the reaction.  
         [0006]     One of the important applications for solid oxide fuel cells (hereinafter referred to as SOFC) are auxiliary power units (APU) for transportation applications. A SOFC APU generates power using hydrogen and carbon monoxide reformed from fuels such as gasoline, diesel, natural gas, biodiesel, and the like.  
         [0007]     SOFC are now considered for distributed power generation with natural gas being the major fuel. Researchers and Industry are looking for lowering the working temperature of these SOFC down to 500 to 700° C. At these medium operating temperature, major innovations can be integrated in the design of the SOFC. The reformer operating temperature should be considered as a major design criterion for the SOFC. Researchers have shown that 500° C. can be considered a lower temperature limit for a high conversion of the natural gas. Furthermore, the overall performance of the SOFC is directly inversely proportional to the electrodes thickness which drives ohmic losses and to the electrolyte thickness which drives the ionic conductivity and operating temperatures of the electrolyte. However, certain considerations of the flow of electrons along the very small thickness of the anode and the cathode will increase the electrical resistivity and special attention has to be given.  
         [0008]     One can distinguish three designs for the SOFC: (a) the cathode supported SOFC (i.e. Westinghouse now Siemens in Pittsburgh), (b) the electrolyte supported SOFC (Siemens Erlangen Germany), and (c) the anode supported SOFC (Centre for Atomic Energy in Julich Germany).  
       SUMMARY OF THE INVENTION  
       [0009]     It is an object of the present invention to provide a new solid oxide fuel cell (SOFC) designed to operate at a temperature ranging between 500 and 700° C. and which addresses the above concerns.  
         [0010]     One aspect of the Invention provides a reformer supported solid oxide fuel cell comprising: a reformer including an electroconductive mixture of an active material and a polymeric ceramic material shaped to constitute a slab having an upper surface and a lower surface and grooves along at least one of the upper surface and the lower surface, and flat regions on at least a section of the periphery of the grooved surface; an anode sprayed onto the grooves of the reformer slab; an electrolyte sprayed onto the anode and the flat regions of the reformer slab; and a cathode sprayed onto the electrolyte, over the grooves of the reformer slab.  
         [0011]     Another aspect of the invention provides a reformer integrated into a solid oxide fuel cell. The reformer comprises a slab of an electroconductive mixture of an active material and a polymeric ceramic material. The slab has waves on a least one surface thereof and a flat surface at least partially surrounding the grooved surface of the slab. The slab is provided with successive layers of an anode material, an electrolyte material, and a cathode material on the waved surface to constitute the solid oxide fuel cell, only the electrolyte material covering the flat surface.  
         [0012]     A further aspect of the invention provides a method for preparing a reformer supported solid oxide fuel cell. The method comprises: shaping a mixture of an active material and a polymeric ceramic material under conditions to constitute a reformer slab having grooves on at least one surface and a flat region extending at least partially in the periphery of the slab; depositing an anode material onto the grooved surface of the slab, the anode material extending short of the flat regions; depositing an electrolyte material onto the anode material and the flat regions; and depositing a cathode material onto the electrolyte material, the cathode material covering the same surface area than the anode material. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0013]     Further features and advantages of the present invention will become apparent from the following detailed description, taken in combination with the appended drawings, in which:  
         [0014]      FIG. 1  is a schematic perspective view of an individual cell in accordance with an embodiment of the present invention;  
         [0015]      FIG. 2  is an exploded view of the individual cell incorporating a reformer in accordance with the invention;  
         [0016]      FIG. 3  is a perspective view, partially sectioned, of a die matrix for producing the reformer in accordance with an embodiment of the present invention;  
         [0017]      FIG. 4  is a perspective view, partially sectioned, of another die matrix for producing the reformer in accordance with another embodiment of the present invention;  
         [0018]      FIG. 5  is an exploded view of a stack design of a cell incorporating the reformer in accordance with the invention;  
         [0019]      FIG. 6  is a graph showing a sintering cycle of the reformer in accordance with the invention;  
         [0020]      FIG. 7  is a graph showing the performance of the reformer in accordance with the invention;  
         [0021]      FIG. 8  is another graph showing the performance of the reformer in accordance with the invention; and  
         [0022]      FIG. 9  is a microstructure of a typical sprayed cell on a reformer support in accordance with the invention. 
     
    
       [0023]     It will be noted that throughout the appended drawings, like features are identified by like reference numerals.  
       DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0024]     The invention relates to a reformer supported SOFC that preferably utilizes nanostructures and operates under medium temperature, such as between approximately 500 and 700° C.  
         [0025]     Referring to  FIG. 1 , it will be seen that onto a reformer  20 , three layers of 5 to 100 micrometers each of an anode  22 , an electrolyte  24  and a cathode  26  are applied.  
         [0026]     An embodiment of an individual cell  30  will now be described with reference to  FIG. 2 . First, a bipolar plate  32  is provided. The bipolar plate  32  is a base metal plate of refractory steel without channel. Typical dimensions of the base metal plate  32  are 0.1×0.1 m to 0.3×0.3 m with a thickness 2 mm or less. The bipolar plate  32  is preferably resistant to corrosion, resistant to reducing conditions (usually H 2 ), and It is preferably dimensionally stable relatively to temperature changes.  
         [0027]     The reformer  20  is prepared by pressing powders having a predetermined composition with a die matrix  40  ( FIGS. 3 and 4 ) that has the negative pattern of the reformer  20 . The reformer consists of a mixture of an active material mixed with up to 30 wt % of polymeric ceramic according to U.S. Pat. No. 4,886,591, for example. The reformer  20  is preferably an electrical conductor. The thickness of the reformer  20  is in the range of 1 to 5 mm and is grooved with channels  36 , or grooves or waves, as shown on  FIGS. 1 and 2 . On  FIGS. 1 and 2 , the reformer  20  has a plurality of longitudinal waves. Referring to  FIG. 3 , it will be seen that grooves  36  are produced by a press (not shown) with a die matrix  40  designed for having a predetermined pattern. One skilled in the art will appreciate that it can also be produced through extrusion, casting or a powder metallurgy punching process. The reformer  20  can also be produced by thermal plasma deposition with a shape forming process in a die matrix  40 .  FIG. 4  shows another possible pattern with radial waves. The grooves or waves  36  allow to increase the active surface of the fuel cell to minimize the stresses, and to insure a gas distribution and an improved electric contact.  
         [0028]     Compaction of the reformer  20  is then followed by a sintering step below approximately 700° C. The reformer  20  is preferably pressed and fired onto the base metal plate  32  to provide sufficient adhesion.  
         [0029]     On the sides of the reformer  20 , along the grooves periodicity, there is a flat region  42 , or flat side or surface, for sealing purpose with the electrolyte  24 , as it will be described more in details later.  
         [0030]     The reformer is then coated with the anode  22  that Is sprayed using a powder or a suspension as precursors onto the reformer  20  including the waves  36 . The sprayed anode  22 , preferably having a thickness between 20 and 100 micrometers, consists of a composite material made of a mixture of electrolyte and metal catalyst. Ceramic anode and more oxidation resistant anode can also be used. The sprayed area stops at the last wave  36   b  and does not extend onto the flat sides  42 .  
         [0031]     The electrolyte  24  is then sprayed onto the whole area of the anode  22  plus the flat sides  42  of the reformer  20 . The electrolyte  24  is a ceramic ionic conductor, for example, it can be stabilized zirconia, cerium oxide doped with a plurality of doping materials such as Gd, Sm or Y or mixtures of both. The electrolyte thickness is preferably in the range of 5 to 50 micrometers.  
         [0032]     Once the electrolyte  24  is sprayed, the cathode  26  is sprayed over with a suspension or powder based spraying technology. A typical cathode  26  is a perovskite material of the type LSM (Lanthanum Strontium Manganate), for example LaSrMnO 3 , LSF (Lanthanum Strontium Ferrite), LSC (Lanthanum Strontium Cobalt), LSCF (Lanthanum Strontium Cobalt Ferrite), SmSrCo, or GdSrCo having a thickness of 50 micrometers or less. The cathode  26  is sprayed onto the electrolyte  24 , covering the same surface area as the anode  22 . Therefore the flat sides  42  are only covered with the electrolyte  24 .  
         [0033]     Even if the anode  22 , the electrode  24 , and the cathode  26  are sprayed by the method described hereinabove, one skilled in the art will appreciate that other deposition methods can be used.  
         [0034]     A fine metal sheet  32  is then put on top and another cell  30  Is added, until a stack or an assembly is obtained.  
         [0035]     Referring now to  FIG. 5 , it will be seen that a number of manufactured individual cells  30  are stacked, or associated, into an assembly  46 . For example, twenty (20) individual cells  30  can be superposed. They are selectively coated with a sealant  48  on the sides to avoid undesired cross flow of gas. The sealant is preferably a high expansion coefficient glass material that wets very well the assembly  46  and the material of a supporting structure  52 . They are also retrofitted with four sidings  50  which are electrically insulated and which should also separate the gas and create a manifold.  
         [0036]     A firing of the assembly  46  is then carried out at a temperature ranging between 500 and 800° C. in order to seal the siding and to relax any residual stresses. The firing should be assisted with a static load applied during the isothermal part of the firing at high temperature for keeping all the cells flat and improving electrical contacts.  
         [0037]     Still referring to  FIG. 5 , there is shown that the supporting structure  52  of the embodiment described is cylindrical with two caps or ends  54 . Electrical contacts  56  are to be provided at each end of the cylindrical supporting structure  52 . The cylinder cap  54  can be specially textured (diaphragm type) to exert a contact pressure which is important for sealing and electrical contact. It also supports a gas inlet  58 , an air inlet  60 , a gas outlet  62 , and an air outlet  64 . Both caps  54  can then be closed by welding for instance, or other sealing means.  
         [0038]     The fuel cells  30  produced in the above described manner are adiabatic SOFC, where the heat generated by the cell operation is used by the endothermal reforming reaction.  
         [0039]     In reformer supported SOFC (RS-SOFC), the reformer has a thickness in the range of millimeters and is a support to build up the anode, the electrolyte and the cathode. The RS-SOFC has preferably a planar geometry but applications with discoidal or tubular geometry are also possible.  
         [0040]     The RS-SOFC is preferably produced by spraying the various layers (anode, electrolyte, and cathode) at various pressures with various technologies such as induction plasma, chemical or physical vapor deposition, DC plasma, thermal spraying and cold gas spraying.  
         [0041]     The reformer preferably has a working temperature In the range of 500 to 700° C. and can accommodate various fuels such as natural gas, methanol, ethanol, gas, kerosene or diesel reforming in-situ in the SOFC. The reformer can preferably accept CO as well as Syngas. The reformer is preferably sulfur tolerant.  
         [0042]     The reformer is composed of nanosized materials, is a porous electrical conductor, and Is preferably resistant to thermal cycles. The reformer can include ruthenium and other catalysers. The reformer preferably minimizes the usual air flow intake because of the possibility of a heat balancing endothermal reaction.  
         [0043]     It is possible to use a graded composition reformer, such as the ones manufactured according U.S. Pat. No. 4,886,591 with modifications to permit the composition gradients, to allow for various kinetic of reactions which take place in the reformer.  
         [0044]     The reformer has preferably a porosity high enough to allow for gas diffusion, to eliminate water and enhance the reforming reaction. The reformer is preferably a heat conductor to provide low temperature gradients in the SOFC.  
         [0045]     The anode which is sprayed onto the reformer contains a percentage of nanosize or microsize grains for higher efficiency. As for the reformer, it is possible to use a graded composition anode. For example, the composition can slowly and gradually change from the anode composition to the electrolyte composition.  
         [0046]     The electrolyte which is sprayed onto the anode and is also used as a sealant for the gas contains a significant percentage of nanosize grains for higher efficiency. Furthermore, the cathode, which is sprayed onto the electrolyte, also contains a significant percentage of nanosize grains for the same reasons.  
         [0047]     The bi-polar plate Is preferably a thin metal sheet.  
         [0048]     The sealing is carried out by glass impregnation or other methods on a selective area.  
       EXAMPLE 1  
       [0049]     In a first example, a reformer, which was also the support of the individual cell, had a composition of 90% wt of nickel and 10 % wt of LaPO 4 . The particles were mechanically screened to obtain particles having a size between 38 and 125 μm.  
         [0050]     0.75 grams of particles were pressed in a 12 mm diameter die matrix having a wavy surface, such as the ones shown on  FIGS. 3 and 4 . The pressure applied was 10 mV during 10 minutes.  
         [0051]     Then, the pressed particles were sintered In a Lindberg sintering furnace with the cycle shown on  FIG. 6  in an argon and hydrogen atmosphere. The porosity of the reformer thus obtained was controlled with an air flow of 150 mm. The porosity control is a crucial step for the performance of the SOFC.  
         [0052]     The support is the surface on which one carries out the deposition of, initially, the anode, then the electrolyte, and finally the cathode. This support must have several qualities. Above all, it must allow the passage of hydrogen. Thus it must be as porous as possible. In addition, if plasma projections are used to deposit the other layers, it is on it that will be carried out the various plasma projections. During these plasma deposition, it undergoes important thermal stresses. It is also part of the unit constituting the cell. Therefore, the support must be resistant to thermal stresses and, particularly, it should not undergo sintering during these various phases of thermal stress. Moreover, since it is used as a support for the cell as its name Indicates, the rigidity of the cell obtained by plasma must be ensured by the support which must have a high mechanical resistance.  
         [0053]     The support is positioned on the anodic side. Therefore, during the operation of the fuel cell, it is subjected to reducing conditions (usually, H 2  at temperatures ranging between 600 and 850° C.). To avoid deformations during the operation of the fuel cell, the support must thus be in its already reduced form. For example, for a nickel support, it must be in the form Ni with the oxidation level zero. It is one of the reasons which requires that the sintering of the substrate support be made under reducing atmosphere.  
         [0054]     If the support must be heated, the oxidizing conditions must be avoided as this would induce an increase of the mass, for example, Ni becoming NiO. Consequently, a deformation of the network and the whole shape of the reformer would occur. This is particularly important if the electrolyte Is already deposited. Indeed, the electrolyte being a ceramic, it is impossible for it to follow the stresses that appear when a massive oxidation of the support material is taking place. If one must heat the unit constituting the cell after the deposition of the various constitutive layers, care must be taken that heating be carried out under an inert atmosphere (N 2 , Ar, He).  
         [0055]     Another characteristic of oxidized support material, for example oxidized nickel, is that it is less mechanically resistant, increasing the cell likeliness of breaking. For example, at the time of preparation of the nickel substrate, a fraction of nickel oxide was Included in the mixture of powders. This was done to increase the porosity of the final substrate. Indeed, while carrying out the sintering of the powders under reducing atmosphere, these oxide powders passed from an oxidation degree of level +11 to level 0, which was accompanied by a loss of mass (NiO: 75 g/mol; Ni: 59 g/mol) accompanied by a reduction in the volume of the particles, which results In an increase of the porosity.  
         [0056]      FIG. 7  shows the performance of the reformer produced by the technique described hereinabove.  
         [0057]     Even if a nickel reformer was produced in the above described example, one skilled in the art will appreciate that the desired properties of the reformer would be similar if other materials are used for the reformer.  
       EXAMPLE 2  
       [0058]     This example relates to the preparation and the evaluation of powdered nickel catalysts for SOFC applications.  
         [0059]     Powdered Ni was supplied by Inco (INCO 255) and was used as received. Reduction of the powder under H 2  atmosphere prior to use did not have any significant effects. The powder had a particle size range from 1 to 20 micrometers in diameter as determined by a Malvern particle sizer. The BET area of the powder was 0.44 m 2 /g. This material was selected because of its irregular surface topology, but other starting types have been used with similar results.  
         [0060]     The raw powder was inserted into a catalytic quartz test tube designed for the reactor system. These quartz tubes supported the catalytic material on a one-cm diameter fritted quartz disk and attached to the source gas supply by a 20 cm long, ¼″ diameter quartz tube. The quartz frit and catalytic material were open to a surrounding quartz envelop which directed the product gases back to the analysis sampling port. The active catalytic region was approximately positioned in the center of a commercial furnace (Omega Engineering Inc.) and the temperature was controlled from ambient to 1000° C. The front door of the furnace was modified to pass seven identical test systems into the heated volume. The dimensions, geometry, and orientation of these test tubes are not critical to the successful operation of the catalyst. Each evaluation was replicated in adjacent tubes, and on repeated runs of the temperature ramp profile.  
         [0061]     0.25 g of the nickel powder was lightly packed onto the quartz frit, and covered by a small plug of quartz wool that serves to prevent blow-through of the catalyst material with the feed-gas flux. The wool also served to maintain the geometric integrity of the nickel powder during the thermal cycling and aggregation process.  
         [0062]     Gas mixtures were prepared using research purity gases (Praxair Inc.) and the ratios were controlled by volumetric rotameters (Omega Engineering Inc.). The H 2 O content of the feed gas was controlled by saturating the feed gas in a glass bubbler; all water was deionized prior to use. The feed gas and product gas compositions were measured using a custom-designed quadrupole mass spectrometer system for real-time measurements. Each sample gas inlet was delivered to the mass-spectrometer system by a pressure reduction manifold, and mass spectra were repeatedly scanned for approximately 1 to 5 minutes prior to the admittance of the next mixture. Signal levels were calibrated in the same apparatus under identical conditions using pure gases. Typical mixtures included CH 4 /H 2 O ratios of 1/1 to 1/3. The results reported herein were obtained with a 1/2 ratio containing 10 torr CH 4 , 20 torr H 2 O and the balance was Ar. The total delivery pressure at the catalyst bed and sampling orifice was approximately 760 torr. The flow rate of the feed gas was 30 ml/min.  
         [0063]     The experiments were performed by monitoring the product gas composition as a function of time with three specific stages: (1) the temperature of the catalyst bed is Increased from 25° C. to 700° C. at a rate of 3° C./minute; (2) a constant temperature phase at 700° C., and finally a cooling cycle at −3° C./minute.  
         [0064]      FIG. 8  shows a typical plot of the CH 4 , H 2 , CO and CO 2  pressures measured at the sampling orifice over the experimental run. It also shows the temperature profile. The sharp reduction in the CH 4  pressure and the increase in the H 2 , CO and CO 2  species demonstrate that the catalyst is active above 325° C., and reaches a maximum at approximately 500° C. At the 700° C. holding temperature of the second phase of the experiment, the measured conversion rate of the methane has exceeded 95%. The gas composition is approximately identical during the first and third phases for a given temperature, Indicating that the catalyst is not suffering measurable degradation over the course of the experiment. The same catalyst material can be reused with no apparent loss of activity.  
       EXAMPLE 3  
       [0065]     The following example concerns the deposition of an anode onto the reformer. The anode was sprayed using spraying parameters described in Table 1 on top of the pressed and sintered reformer. A nitrate solution-suspension was used but a powder can also be used.  
                   TABLE 1                           Anode material:   NiO       Electrolyte material [GDC, SDC or others]:   GDC       Solution - Anode       Anode - Raw material [Nitrate or others]:   Nitrate       Exact chemical composition (including hydratation):   Ni(NO 3 ) 2  * 6H 2 O       Anode salt weight [g]:    40.8628       Solution - Electrolyte       Electrolyte - Raw material [Nitrate or others]:   Nitrate       Exact chemical composition (including hydratation):   Ce(NO 3 ) 3  * 6H 2 O       Electrolyte salt weight [g]:    56.4806       Additive - Raw material [Nitrate or others]:   Nitrate       Exact chemical composition (including hydratation):   Gd(NO 3 ) 3  * 6H 2 O       Additive salt weight [g]:    14.551       Molar ratio additive/electrolyte [% wt]:    25       Plasma deposition       Plasma torch [PL-35, PL-50]:   PL-50       Nozzle diameter [mm]:    45       Nozzle type:   Standard       Sheathing gas [O 2 , Ar, or others]:   O 2         Sheathing gas flowrate [mm]:   108       Plasmagene gas (central) [O 2 , Ar, or others]:   Ar       Plasmagene gas flowrate [mm]:    32       Carrying gas (powder) [O 2 , Ar, or others]:   Ar       Carrying gas flowrate [mm]:    80       Plate voltage [kV]:    7.2       Plate electric current [A]:    5.1       Grid electric current [A]:    0.55       Calculated power [kW]:    36.72       Operating pressure [Torr]:    51.1       Number on the specimen carrier:    1       Position on the specimen carrier:    4       Pump speed:    3.5       Spraying distance [mm]:   200       Probe depth [mm]:   160       Controller parameters       Number of passes:    10       Rotation number:    3       Rotation angle:   Between 9h00           and 16h00       Offset position [mm]:    50       Specimen carrier speed [mm/s]:    50       time 0 (Rest at the offset) [s]:    10       time 1 (Rest at the opposite extremity) [s]:    4                  
 
       EXAMPLE 4  
       [0066]     The electrolyte was sprayed on top of the anode with the spraying parameters described in Table 2. Nitrates were used but a powder can also be used. A supersonic nozzle was used to achieve a high density of the electrolyte material.  
                   TABLE 2                           Electrolyte material [GDC, SDC or others]:   GDC       Solution - Electrolyte       Electrolyte - Raw material [Nitrate or others]:   Nitrates       Exact chemical composition (including hydratation):   Ce(NO 3 ) 3  * 6H 2 O       Electrolyte salt weight [g]:   146.742       Additive - Raw material [Nitrates or others]:   Nitrates       Exact chemical composition (including hydratation):   Gd(NO 3 ) 3  * 6H 2 O       Additive salt weight [g]:    37.79       Molar ratio additive/electrolyte [% wt]:    25       Plasma deposition       Plasma torch [PL-35, PL-50]:   PL-50       Supersonic flow [Yes or No]:   Yes       Sheathing gas [O 2 , Ar, or others]:   O 2         Sheathing gas flowrate [mm]:   102; 108       Plasmagene gas (central) [Ar or others]:   Ar       Plasmagene gas flowrate [mm]:   40; 30       Carrying gas (powder) [O 2 , Ar, or others]:   Ar       Carrying gas flowrate [mm]:   40; 80       Plate voltage [kV]:   7.5; 8.8       Plate electric current [A]:   5.2; 6.2       Grid electric current [A]:   0.6; 0.65       Calculated power [kW]:   39.0; 54.56       Operating pressure [Torr]:   58.0; 50.5       Number on the specimen carrier:    1       Position on the specimen carrier:    4       Pump speed:    3.5       Spraying distance [mm]:   200       Probe depth [mm]:   155       Controller parameters       Number of passes:   15; 15       Offset position [mm]:    50       Specimen carrier speed [mm/s]:    50       time 0 (Rest at the offset) [s]:    10       time 1 (Rest at the opposite extremity) [s]:    0.5                  
 
       EXAMPLE 5  
       [0067]     The cathode is the last coating that is carried out and suspensions and solutions have been used. One skilled in the art will appreciate that powders can be used instead of suspensions and solutions.  
                   TABLE 3                           Cathode material [LSC or others]:   LSC       Solution data           117.7500 g La(NO 3 ) 3  * 6H 2 O           14.5148 g Sr(NO 3 ) 2             100.8397 g Co(NO 3 ) 2  * 6H 2 O           40 g Glycine           200 ml H 2 0       Cathode       Raw material [Nitrate or others]:   Nitrate       Plasma Deposition       Plasma torch [PL-35, PL-50]:   PL-50       Supersonic flow [Yes or No]:   No       Nozzle diameter [mm]:    45       Sheathing gas [O 2 , Ar, or others]:   O 2         Sheathing gas flowrate [mm]:   108       Plasmagene gas (central) [Ar or others]:   Ar       Plasmagene gas flowrate [mm]:    30       Carrying gas (powder) [O 2 , Ar, or others]:   Ar       Carrying gas flowrate [mm]:   100       Calculated power [kW]:    35       Pump speed [ml/min]:    20       Spraying distance [mm]:   225       Probe depth [mm]:   160       Controller parameters           Preheating       Number of passes:    4       Rotation number:    0       Rotation angle:    0       Rotation speed:    0       Offset position [mm]:    50       Specimen carrier speed [mm/s]:    35       time 0 (Rest at the offset) [s]:    10       time 1 (Rest at the opposite extremity) [s]:    0                  
 
       EXAMPLE 6  
       [0068]     The open circuit voltage (OCV) obtained was 650 mV. The bench test was operated with H 2  at 18 ml/min and air. Some other results with CH 4  at 5 ml/min show a OCV of 700 mV and a very low power density of 2,1 mW/cm 2 .  
         [0069]      FIG. 8  shows a microstructure of a typical sprayed cell on a reformer support.  
         [0070]     The embodiments of the invention described above are intended to be exemplary only. For example, the experimental parameters used to produce a fuel cell in the above described examples can be modified in accordance with the size, the composition, and the properties of the fuel cell. The scope of the invention is therefore intended to be limited solely by the scope of the appended claims.