SODIUM BETA ALUMINA ELECTROLYTE ELEMENTS AND THEIR MANUFACTURE

Abstract: In producing β/β″ alumina, finely divided zirconia (typical­ ly 0.1 to 3% by weight) is included in the precursor materials before sintering whereby, during subsequent sintering, any calcia present as an impurity is dissolved in the zirconia forming stabilised cubic or tetragonal phase zirconia as a discrete phase in the β/β″ alumina matrix. By this technique, the effect of cal­ cium impurities on the ratio of β″ to β can be reduced or elimi­ nated.

Description: SODIUM BETA ALUMINA ELECTROLYTE ELEMENTS AND THEIR MANUFACTURE Sodium beta alumina, commonly called beta alumina is a ceramic mixed oxide material which is ionically conductive for sodium ions. In many applications, for example in sodium sulphur cells, high conductivity is a desirable or necessary characteristic. The beta alumina is predominately formed of sodium oxide (Na2O) and alumina (A1203) and exists in two distinct phases p and n, In the fl or 2-block form, the spinel blocks in alternate planes are of mirror image form whereas, in the " or 3-block form, the orientation of the spinel blocks in successive planes are at angles such that the spinel block orientations are repeated in every third plane. The /" phase has a much higher ionic conductivity than the fi phase and therefore, in making beta alumina electrolyte material for use where high conductivity is required, it is desirable to produce, as far as possible, the /" phase. In general, the electrolyte will consist of at least 50% by weight of t " alumina and preferablyinexcess of 80% by weight of #" alumina, and more preferably in excess of 90% by weight of /" alumina. In order to produce /" alumina, it is now known that a stabiliser, usually Li20 or MgO, should be included and also that the soda content (Na2O) must be sufficient, typically above about 8% by weight. Present-day production techniques using sufficient soda and using a stabiliser produce a material which is a mixture of the fi and / " phases and which will be referred to as f/# // " alumina. The proportion of the two phases and hence the ionic conductivity has been found to depend on the proportions of soda, alumina and stabiliser, and on the manufacturing or processing conditions. It is possible to vary the proportions of Band " phases within certain limits by appropriate choice of chemical composition and of processing conditions, but such conditions are determined primarily by the requirement of obtaining a fl/A" alumina ceramic that possesses low porosity, high mechanical strength and resistance to environmental (atmospheric) attack. We have found that, for a given chemical composition and given processing conditions, the presence of calcium as an impurity in f/A " alumina causes a decrease in the ionic conductivity which is, in part, attributable to a decrease in the proportion of F " to / phase. This effect of calcium on the ratio of P to P n alumina occurs at very low calcium levels and is to be distinguished from the effect of calcium addition in relatively large quantities to single phase fi alumina causing reduced conductivity as reported in the paper "Production of B A1 0 Electrolyte" by I.W.Jones and L.J.Miles, Proc. 2 3 Brit. Ceram. Soc. 1971 No.19 pages 161-178, and by A.C.Buechele and L.C. de Jonghe in "Microstructure and Ionic Resistivity of Calcium-Containing Sodium Beta Alumina" Ceramic Bulletin Vol. 58 No.9 (1979) pages 861-864. It is known to toughen or strengthen / alumina by the addition of zirconia stabilised in the tetragonal form by rare earth oxides; see for example U.S. 4358516. This technique however leads to a substantial increase in resistivity. The present invention is concerned with obtaining high conductivity in the two phases #/r4 " electrolyte material and with overcoming the deleterious effects of impurities, notably calcium, therein. In such material, the presence of calcium, even in very small quantities, such as 100 ppm by weight, will cause a significant increase in resistivity of the electrolyte and will also cause degradation of resistance stability of the electrolyte when used in a sodium sulphur cell. One way of obtaining a higher proportion of P " alumina and a higher conductivity in fi/7? " material would be to eliminate any calcium; this however requires not only high purity and therefore expensive starting materials but also requires prevention of any contamination of the material during the grinding and other manufacturing operations. The present invention is directed more particularly to the reduction or elimination, during manufacture, of the adverse effects of calcium on the A " to '3ratio, the conductivity and the resistance stability of ft/j9 " alumina. According to one aspect of the present invention, in the production of a B/B¯ alumina electrolyte element by sintering finely powdered p/p " alumina or precursor material comprising alumina, soda and a stabiliser, which stabiliser comprises lithium and/or magnesia, or materials which provide on heating the alumina, soda and stabiliser, there is included in the mixture, before sintering, finely divided zirconia, whereby, during subsequrent sintering, calcia interacts with, reacts with, or dissolves in, the zirconia in such a way that the deleterious effects of calcia on electrolyte conductivity, and on resistance stability during charge-discharge cycling in cells, are suppressed or rendered innocuous. The mechanism by which this is most likely to occur is the dissolution of the calcium impurity in the zirconia. The zirconia phase remains as a discrete second phase in the P / " alumina matrix, thereby removing the calcium from the conduction planes and grain boundaries of the fl/i? " alumina. This mechanism has been shown by electron microprobe analysis to occur in /?/# " alumina containing several percent by weight of zirconia. At low levels of zirconia addition the mechanism could not be verified by direct observation, but it-is clear from electrical resistivity measurements that an interaction between zirconia and calcia is present in sintered B/p " alumina ceramics even at very low levels of zirconia addition. For the purposes of enhancing electrolyte conductivity it is only necessary to add sufficient zirconia to overcome the deleterious effects of the calcium present. Using commercial grade materials for making the mixture, the amount of zirconia required might be 0.1 to 25% by weight of the total weight of material being sintered, but, as zirconia is a non-conductor, an excess is undesirable and 0.1 to 15% by weight is preferred and more preferably 0.1 to 3%. The above-described technique can beneficially be used with E / " alumina containing 10 to 1000 ppm by weight (measured as calcia) of calcium impurity, enabling a ceramic to be produced predominately in the P " phase rather than in the P phase. Typically a proportion of 80% by weight of the r " phase may be obtained. The zirconia may be added as powdered zirconium oxide (Zr02) or as a zirconium compound which produces Zero, on heating. Zr02 is a polymorphic material which normally exists at room temperature in a monoclinic form. At high temperatures, the monoclinic form is transformed first to a tetragonal form and then to a cubic form. The tetragonal and cubic forms are stabilised by dissolution of calcia so that these crystalline forms are retained on cooling. Whether the tetragonal or cubic form is produced will depend, inter alia, on the temperature employed for sintering the beta alumina but, at the temperatures normally employed, it is to be expected that the tetragonal form will predominate. However both the cubic and tetragonal forms will retain the calcia in solution on cooling and will remain as a discrete phase within the fl /p " matrix. The addition of the zirconia thus serves to prevent any calcium which may be present in the original mixture from affecting the proportion of g " alumina to fl alumina in the final product. The amount of zirconia added (typically 0.1 to 3% by weight) should be chosen to be sufficient to eliminate the effects of all the calcium which might be present. The addition of the small quantity of zirconia required to eliminate the effects of calcium impurities has been found to give a significant improvement in the ionic conductivity of / // " alumina due in part to the enhancement of the ratio of the " to ss alumina. An increase, for example, from 50% to 80% in the proportion of to n to / alumina causes a large increase in conductivity since the conductivity of / " alumina, measured on a single crystal, is many times, possibly 20 times, that of fi alumina. The invention furthermore includes within its scope a A/A" alumina electrolyte element containing at least 50% by weight of ss " alumina and containing zirconia (preferably 0.1 to 3% by weight of zirconia) dispersed as a second phase in a matrix of J?/A " alumina, at least some of the zirconia being of cubic or tetragonal phase stabilised by dissolved calcia. The following experimental results demonstrate the benefits obtained by adding a small quantity of zirconia to the powdered mixture before firing in the production of fl/i? " alumina ceramic electrolyte material. Examples 1, 3, 5 , 8; 11, 17 and 19 below are for comparison purposes only and are not-examples of the invention. Examples 1-9 These examples 1 to 9 are set out in Table 1 below. In each of examples 1 to 7 a mixture was made of finely powdered oxide material of composition, by weight, of 8.6% Na20, 1.0% MgO, 0.5% Li2 0, balance Awl203. The source alumina powder, commercially available under the trademark "Alcoa A16SG superground", was found by chemical analysis to contain in the region of 100-200 ppm CaO. The mixed powdered material was slurry-solution spray-dried, isostatically pressed into the form of a tube and then fired using a zone sintering furnace as described in U.K.Patent Specifications 1297373, 1375167, 1458221 and 1458222. The chemical analyses disclosed in the examples listed in Table 1 refer to tfle' CaO content of the tube after firing and annealing in the known way. The electrical resistivity of the sintered material was measured after firing and annealing. In examples 1 and 2 an extra grinding operation was incorporated into the powder preparation process and the presence of calcia in these examples substantially in excess of that in the source alumina indicates that extra calcia had been absorbed by the powder during the process. In examples 1, 3 and 5 no zirconia was added. These examples are for comparison purposes only. In examples 2, 4, 6 and 7 monoclinic zirconia powder was mixed with the precursor powder prior to spray-drying. The proportion of added zirconia was 0.15% or 0.20% by weight. These examples serve to illustrate the present invention. TABLE 1 Fired CaO z#2 %#" Resistivity Firing Density Impurity Addition in //P" at 350 C Exanple Method (g/cmJ) ppm W/O Phase (ohm cm) 1 zone 3.216 525 0 56 7.9 2 zone 3.206 550 0.2 60 5.9 3 zone 3.215 200 0 60 6.3 4 zone 3.196 200 0.2 68 4.6 5 zone 3.207 160 0 62 6.2 6 zone 3.192 150 0.2 72 4.4 7 zone 3.217 100 0.15 66 4.7 8 batch 3.217 160 0 86 9 batch 3.200 200 0.2 91 3.4 In examples 8 and 9 the tube forming process was identical to that in examples 1 to 7, but the tubes were sintered in an isothermal batch sintering furnace using a two-peak firing process as described in British Patent No.1,558,305. No zirconia was used in example 8, which is for compariton puEpo8es only. Examples 1 to 9 are listed in Table 1 wherein the proportion of / r alumina in the fl/7? 'I mixture was determined by X-ray powder diffractometry, and the electrical resistivity at 3500C, this temperature being the normal operating temperature of a sodium sulphur cell, was determined by means of a four-point direct current technique. Comparison of examples 2, 4 and 6 with examples 1, 3 and 5 respectively indicates that in zone-sintered material of a given level of calcium impurity, the presence of 0.2 per cent by weight of zirconia results in an increase in the proportion of fi n alumina and a lowering of the resistivity at 3500C. Comparison of example 9 with example 8 also indicates an increase in the proportion of /" alumina when zirconia is added. Example 10 Early sodium sulphur cells, containing electrolyte of the composition 8.6% Na20, 1.0% MgO, 0.5% Li20, balance Awl2 03 generally exhibited severe resistance increase following charge-discharge cycling. In these cells no zirconia was present in the electrolyte and the calcium oxide content was typically in the range 200-500 ppm. The rate of resistance increase in these cells ranged from 5% to 500% per 100 cycles of operation, the average being approximately 20% increase in resistance per 100 cycles. In example 10, eighteen zone-sintered tubes of the composition 8.6% Na20, 1.0% MgO, 0.5% Li20, balance Al 0 were assembled into sodium sulphur cells to function 23 as electrolytes therein. It will be noted from Table 2 below that the electrolyte material had considerably less calcium oxide content than the material mentioned in the preceding paragraph but otherwise was of similar composition. The cell resistance of each of these cells was measured over a period of approximately 250 days or 800 charge-discharge cycles. The results are indicated in Table 2. The two cell types N and R are distinguished by different types of sulphur electrode, which have different resistivities. Within each cell type, the presence of added zirconia in the electrolyte, shown by the suffix "b" to the series No., results in a lowering of the cell resistance by approximately 15 per cent compared with the cells (suffix "a") without added zirconia. TABLE 2 Min CelL t Change in Resistance Resistance (ra) per 100 ZrO2 CaO Electrolyte ¯¯¯¯¯¯¯¯¯¯¯¯ Cycles No of Cell Content Content Resistivity Series Cells Type (wiz) ppm Coba ca) Fean S.D. Hean S.D. 1a 3 N 0 160-200 6.2-6.3 22.1 1.1 -0.78 0.12 Ib 4 N 0.2 150-200 4.4-4.6 19.3 1.2 +0.38 1.91 2a 6 R 0 160-200 6.2-6.3 17.2 0.4 +0.15 0.35 2b 5 R 0.15 100-200 4.7-5.0 14.7 0.7 -0.99 O.U la+2a 9. N+R 0 150-200 -0.16 0.54 lbF2b 9 NER 0.15-0. 1C0-230 -0.38 1.41 S.D. - Standard Deviation The resistance stability of each cell was assessed by determining the percentage change per 100 cycles, between the cell's most recent or final resistance, and the initial resistance, namely the resistance after a few running-in cycles. In Table 2 it is observed that all cells had very stable resistances, the final resistance often being slightly lower than the starting resistance. The presence of zirconia in the electrolyte did not appear significantly to influence resistance stability, probably because the calcium content was sufficiently low in all cells. It is possible that the presence of zirconia may allow somewhat higher levels of calcium impurity to be tolerated, without encountering problems of resistance rise. -The present example serves only to demonstrate that the presence of zirconia in the electrolyte does not adversely affect resistance stability. Examples 11 -16 In these examples, which are set out in Table 3 below, the effect of additions of zirconia at levels varying from zero to 3 per cent by weight on the electrolyte conductivity, ratio of " to /3 phase, and crystal lattice parameters was determined. Beta/Beta" alumina tubes were formed from the composition by weight 8.75% Nag0, 0.75% Li20, balance Awl203, using the method of electrophoretic deposition disclosed in U.S.Patent 3,881,661 and fired by means of the two-peak batch sintering method used in Examples 8 and 9. A mixture was made of the finely powdered oxide material, which was then calcined to convert to fl/A " alumina powder and vibro-energy milled in waterfree l-pentanol with alumina grinding media. For a level of Zr02 addition of 0.3 per cent by weight, stabilised zirconia grinding media were used in place of alumina, the wear by abrasion of the grinding media providing the finely divided zirconia in the suspension. For levels of Zr02 addition greater than 0.3 per cent by weight, monoclinic Zr02 powder was added to the powder mix to make up the difference. Following electrophoretic deposition of the powder in the form of a tube, the deposit was allowed to dry and the green shape was sintered using the two-peak firing process, with peak temperatures of 14700C and 16400C respectively. In Table 3 the proportions of zirconia refer to the total amount of Zr02 present in the ss/ss" alumina tube, and include the amount obtained from wear of the zirconia grinding media. In example 11 alumina grinding media were used in place of the zirconia; this example is for comparison purposes. The resistivity measurements in Table 3 were made at room temperature by means of a 4-point AC technique. TABLE 3 Rumple Weight Z Weight Z Fired z ssn in Resistivity Lattice Paraseter of Zero, added CaO added (gici3) ss/ss" phase at 200C f phase (kilobs Q) a c 11 0 - 3.123 83 0.73 5.6095 33.460 1233.460 0.3 - 3.219 89 0.52 5.6101 33.454 13 0.6 - 3.225 88 0.45 5.6094 33.466 14 1.0 - 3.250 92 0.48 5.6099 33.457 15 2.0 - 3.262 92 0.47 5.6100 33.456 16 3.0 - 3.287 93 0.49 5.6101 33.455 17 0 0.1 3.150 85 0.80 5.6094 33.460 18 1.0 0.1 3.207 90 0.48 5.6098 33.459 In examples 11-16 it is observed that as the proportion of zirconia is increased from zero the proportion of / " in the <RTI ID=14.13> B /ss " "alumina mixture increases and the electrical resistivity decreases. At levels of ZrO2 greater than approximately 1 per cent by weight there is substantially no further increase in the proportion of /", and no further decrease in the electrical resistivity. Examples 17-18 In these examples, which are set out in Table 3 above, tubes were formed by electrophoretic deposition and fired by the batch sintering method. Alumina grinding media were used in vibromilling the suspension, and calcia was deliberately added to the powder mix in order to demonstrate the deleterious effects of this impurity on the electrical resistivity of the ceramic and to demonstrate the effectiveness of added zirconia in counteracting such an effect. In example 17 1000 ppm by weight of CaO was added; this example is for comparison purposes only. In example 18 1000 ppm by weight of CaO and 1 per cent by weight of monoclinic zirconia powder were added. This example serves to illustrate the present invention. The results listed in Table 3 indicate that addition of the zirconia powder results in a small increase in the proportion of / #" in the fi // '# alumina mixture and in a substantial decrease in the electrical resistivity. The crystal lattice parameter measurements in Table 3, obtained by an accurate back-reflection X-ray diffraction technique, indicate that there is no significant change in the lattice parameters of the /" alumina phase as the zirconia content is increased from zero to 3 per cent by weight. These measurements indicate that at all levels of addition the zirconia remains as a discrete second phase and does not dissolve into the fl/A'" alumina matrix. Microstructural and SEM/EDAX (scanning electron microscope/energy dispersive analysis by X-rays) examination of similar material also indicate that the zirconia remains as a discrete second phase. Electron microprobe analysis showed that a high level of calcium was present in the zirconia phase, considerably higher than could be accounted for by impurities in the source zirconia. These observations provide direct confirmation that the zirconia has the desired effect of eliminating calcium from the fl/#" alumina phase. Examples 19-21 In these examples a mixture was made of finely powdered oxide niaterial ol composition, by weight, of 8.0% Na2O, 2.0% MgO, balance A1203. Beta/beta" alumina tubes of this composition were formed and fired bymeans of the process described in Examples I to 7. The resistivity was measured at 3000C and 3500C by a 4 point direct current technique and the results are shown in Table 4. In example 19 no zirconia was added, this example is for comparison purposes only. The resistivities quoted in Table 4 for this example represent the minimum values obtained from a large number of tubes, namely 3 standard deviations below the mean. Table 4 Weight Z Resistivity (ohm cm) Example ZrO2 added 3000C 3500C 19 0.0 11.26 8.23 20 7.0 9.94 7.71 21 13.0 10.84 8.25 In examples 20 and 21, 7X by weight and 13% by weight respectively of monoclinic zirconia powder was added to the powder mix. Tubes were formed and fired in a manner identical to that in example 19. These examples serve to illustrate the invention. The values for resistivity quoted for examples 20 and 21, which are single measurements, indicate that a substantial reduction is resistivity may be obtained even when a relatively high proportion of zirconia is introduced.

Claims: CLAIMS: 1. A process for producing a //p " alumina electrolyte element by sintering finely powdered p// II alumina or precursor material comprising alumina, soda and a stabiliser which stabiliser comprises lithic and/or magnesia, or materials which provide, on heating, the alumina, soda and stabiliser, characterised in that there is included in the mixture, before sintering, finely divided zirconia, whereby, during subsequent sintering, calcia is dissolved in the zirconia forming stabilised cubic or tetragonal phase zirconia as a discrete phase in a alumina matrix, the amount of zirconia added being sufficient to dissolve substantially all the calcium present in the mixture being sintered. 2. A process as claimed in claim 1 wherein the amount of zirconia is 0.1 to 25% by weight of the total weight of material sintered. 3. A process as claimed in claim 1 wherein the amount of zirconia is 0.1 to 15% by weight of the total weight of material sintered. 4. A process as claimed in claim 1 characterised in that the amount of zirconia is 0.1 to 3% by weight of the total weight of material sintered. 5. A process as claimed in any of the preceding claims characterised in that the mixture being sintered contains 10 to 1000 ppm by weight of calcium (measured as calcia) as an impurity. 6. A fl/fl " alumina electrolyte element containing at least 50% by weight of A" alumina and containing zirconia dispersed as a second phase in a matrix of P/A " alumina, at least some of the zirconia being of cubic or tetragonal phase stabilised by dissolved calcia. 7. A // " alumina electrolyte element as claimed in claim 6 wherein the amount of zirconia is 0.1 to 25% by weight of the weight of the element. 8. A fl/fl" alumina electrolyte element as claimed in claim 6 wherein the amount of zirconia is 0.1 to 15% by weight of the weight of the element. 9. A B/B " alumina electrolyte element as claimed in claim 6 characterised in that the amount of zirconia is 0.1 to 3% by weight of the weight of the element. 10. A A/A " alumina electrolyte element as claimed in any of claims 6 to 9 and containing 10 to 1000 ppm by weight of calcium (measured as calcia) as an impurity. 11. A ss/ss " alumina electrolyte element as claimed in any of claims 6 to 10 wherein substantially all the calcium present is dissolved in the zirconia. 12. A fl/P " alumina electrolyte element as claimed in any of claims 6 to 11 and comprising 80% ss " alumina by weight.

Inventors: HEAVENS, STEPHEN NICOLAS, DR.
Applicants: CHLORIDE SILENT POWER LIMITED
Application year: 1983
Main classification: C04B35
IPC codes: H01M10, C04B35