Abstract:
In accordance with certain embodiments of the present disclosure, a method for fabricating a solid oxide fuel cell is described. The method includes synthesizing a composition having a perovskite present therein. The method further includes applying the composition on an electrolyte support to form an anode and applying Ni to the composition on the anode.

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     The present application claims is based on and claims priority to U.S. Provisional Application Ser. No. 61/404,996, filed Oct. 13, 2010, which is incorporated by reference herein in its entirety. 
    
    
     GOVERNMENT SUPPORT CLAUSE 
     The present invention was developed with funding from the US Department of Energy under award DE-SC0001061. Therefore, the government retains certain rights in this invention. 
    
    
     BACKGROUND 
     Solid oxide fuel cells (SOFCs) can potentially utilize hydrocarbon fuels without precious metal catalysts. As methane is the simplest hydrocarbon fuel and natural gas (with methane as the main component) is readily available, direct-methane SOFCs have attracted great attention and the catalytic activity of the anode materials plays an important role for this application. Among the non-precious metals, Ni shows impressive catalytic activity in steam-reforming methane, but suffers significant carbon deposition under low steam content which is mainly caused by methane thermal cracking. Such degradation can be mitigated by selection of appropriate catalyst supports and by control of the particle size, dispersion and stabilization of the metallic catalyst particles. However, these strategies are not suitable for the conventional Ni-cermet anode since it usually contains a large volume ratio of Ni to maintain sufficient electrical conductivity. This feature makes it easier for carbon formation to occur on the excessive Ni surface. Additionally, the large ratio of Ni tends to cause the anode sintering at high operating temperatures and more serious volume change during redox cycles. 
     Mixed ionic and electronic conductors (MIECs) have recently been explored as anode materials for direct-hydrocarbon SOFCs. However, the electrical conductivity and the catalytic activity of the most reported MIEC ceramics are still not satisfactory. Without precious metal catalysts, the cell performances are limited, especially when directly operated with hydrocarbon fuels. 
     Thus, improvements in anode materials are desirable. 
     SUMMARY 
     Advantages of the invention will be set forth in part in the following description, or may be obvious from the description, or may be learned through the practice of the invention. 
     In accordance with certain embodiments of the present disclosure, a method for fabricating a solid oxide fuel cell is described. The method includes synthesizing a composition having a perovskite present therein. The method further includes applying the composition on an electrolyte support to form an anode and applying Ni to the composition on the anode. 
     In certain aspects of the present disclosure, a solid oxide fuel cell is disclosed. The solid oxide fuel cell includes an anode having a perovskite on an electrolyte support. The electrolyte support of the anode further includes Ni. 
     Other features and aspects of the present disclosure are discussed in greater detail below. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       A full and enabling disclosure, including the best mode thereof, directed to one of ordinary skill in the art, is set forth more particularly in the remainder of the specification, which makes reference to the appended figures in which: 
         FIG. 1  illustrates XRD pattern of the mixed powder of SFMO and NiO in accordance with certain aspects of the present disclosure. 
         FIG. 2  illustrates a cross-sectional view of a cell with a Ni modified SFMO (Ni-SFMO) anode in accordance with certain aspects of the present disclosure. 
         FIG. 3  illustrates the performance of fuel cells with either Ni-SFMO anode or SFMO anode in accordance with certain aspects of the present disclosure. 
         FIG. 4  illustrates the performance stability of cells with the Ni-SFMO anode in CH 4  in accordance with certain aspects of the present disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     Reference now will be made in detail to various embodiments of the disclosure, one or more examples of which are set forth below. Each example is provided by way of explanation of the disclosure, not limitation of the disclosure. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present disclosure without departing from the scope or spirit of the disclosure. For instance, features illustrated or described as part of one embodiment, can be used on another embodiment to yield a still further embodiment. Thus, it is intended that the present disclosure covers such modifications and variations as come within the scope of the appended claims and their equivalents. 
     Recently, a novel perovskite Sr 2 Fe 1.5 MO 0.5 O 6  (SFMO) has been described in U.S. patent application Ser. No. 13/020,356, incorporated by reference herein, to show high electrochemical performance as an anode material in SOFCs operating with hydrogen as fuel wherein the relatively high electrical conductivity can promote the catalytic activity of other metallic catalysts. Accordingly, dispersing a small amount of Ni on the SFMO anode as catalyst can improve the anode performance while avoiding carbon deposition from the conventional Ni-cermet anode for direct methane SOFCs. 
     In the present disclosure, La 0.8 Sr 0.2 Ga 0.83 Mg 0.17 O 3  (LSGM) electrolyte supported single cells with La 0.6 Sr 0.4 Co 0.2 Fe 0.8 O 3  (LSFC) as the cathode and Ni-modified SFMO as the anode were fabricated for direct utilization of methane fuel. The LSGM electrolyte substrate was made from pressing LSGM pellets and then sintering at 1400° C. for 5 h. The inks of anode SFMO (with 10 wt % pore former) and cathode LSCF were then screen printed on the two sides of the LSGM electrolyte pellet. The effective area of the electrode was controlled by the area of the cathode which was about 0.33 cm −2 . The anode and the cathode together with the LSGM electrolyte were then co-fired in air at 1100° C. for 1 h. For the Ni modified anode, the SFMO anode of the co-fired cell was infiltrated with Ni(NO 3 ) 2  solution and then fired at 500° C. for 1 h prior to the electrochemical testing. 
     Since Au is inert to methane oxidation, Au paste was used as the contact layer for current collection on the anode surface. Ambient air was used as oxidant. The flow rate of the fuel gas was set at 40 ml min −1 . Prior to any electrochemical measurement, the cell was stabilized for 10 h when the fuel gas was switched from H 2  to CH 4 . Fuel cell performance was measured with a Versa STAT 3-400 test system (Princeton Applied Research). Introduction of a small amount of Ni phase in the SFMO anode significantly enhanced the cell performance in both H 2  and CH 4 . With the ambient air as the oxidant, the peak power density of the fuel cells with t SFMO as anode is 0.291 W cm −2  in wet H 2  (3 vol % H 2 O) and only 0.033 W cm −2  in wet CH 4  (3 vol % H 2 O) at 800° C. With the same testing conditions, the peak power density of fuel cells with Ni-SFMO as anode reaches 1.134 W cm −2  in wet H 2  (3 vol % H 2 O) and 0.669 W cm −2  in wet CH 4  (3 vol % H 2 O). Further, the cell performance is also stable when operating with CH 4  fuel, indicating that the carbon formation on Ni surface can be suppressed by controlling the dispersion and loading about 0.1 to about 5 weight percent of Ni on the SFMO anodes. Considering the simple anode fabrication procedure and the relatively low cost of the anode materials, Ni modified SFMO ceramic anode shows great promise for direct-methane solid oxide fuel cells. 
     The following examples are meant to illustrate the disclosure described herein and are not intended to limit the scope of this disclosure. 
     EXAMPLES 
     In this study, La 0.8 Sr 0.2 Ga 0.83 Mg 0.17 O 3  (LSGM) electrolyte supported single cells with La 0.6 Sr 0.4 Co 0.2 Fe 0.8 O 3  (LSFC) as the cathode and Ni-modified SFMO as the anode were fabricated and tested for direct utilization of methane fuel. The reason for using SFMO as anode material is its high electrical conductivity and redox stability. A small amount of NiO (˜2 wt %) was applied to modify the performance of the ceramic anode by infiltrating the SFMO anode with nickel nitrate solution followed by heat-treatment. The chemical compatibility between NiO and SFMO, the single cell performance as well as the cell performance stability of the Ni-modified SFMO anode using wet CH 4  (3% H 2 O) as fuel were evaluated. 
     The SFMO powders were synthesized by a microwave-assisted combustion method. Sr(NO 3 ) 2 , Fe(NO 3 ) 3 .9H 2 O and (NH 4 ) 6 Mo 7 O 24 .4H 2 O purchased from Alfa Aesar with high purity were used as metal precursors. Glycine and citric acid were used to assist the combustion process. The as-prepared ash was fired at 1000° C. for 5 h to form the perovskite structure. The LSGM electrolyte material was synthesized by the solid-state reaction and the LSCF cathode material was made by a citric-assisted combustion method. 
     Powder X-ray diffraction (XRD) patterns were recorded on a D/MAX-3C X-ray diffractometer with graphite-monochromatized Cu K α radiation (λ=1.5418 Å) at a scanning rate of 5° min −1  in the 2θ range of 10°-90°. Microstructural features were characterized by scanning electron microscopy (SEM, FEI Quanta and XL 30) equipped with an energy dispersive spectrometer (EDS). 
     Single cells were fabricated on the LSGM electrolyte substrate made from pressing LSGM pellets and then sintering at 1400° C. for 5 h. The inks of anode SFMO (with 10 wt % pore former) and cathode LSCF were then screen printed on the two sides of the LSGM electrolyte pellet. The effective area of the electrode was controlled by the area of the cathode which was about 0.33 cm −2 . The anode and the cathode together with the LSGM electrolyte were then co-fired in air at 1100° C. for 1 h. For the Ni modified anode, the SFMO anode of the co-fired cell was infiltrated with 0.5M Ni(NO 3 ) 2  solution and then fired at 500° C. for 1 h prior to the electrochemical testing. 
     Since Au is inert to methane oxidation, Au paste was used as the contact layer for current collection on the anode surface. Ambient air was used as oxidant. The flow rate of the fuel gas was set at 40 ml min −1 . Prior to any electrochemical measurement, the cell was stabilized for 10 h when the fuel gas was switched from H 2  to CH 4 . 
     The chemical compatibility between SFMO and NiO was investigated by firing the mixed powders of SFMO and NiO (50:50 wt %) at 1000° C. for 10 h in air. The XRD pattern of the mixed powder is shown in  FIG. 1 . Only XRD peaks corresponding to those of NiO and SFMO are present, indicating that there is no chemical compatibility issue for Ni modified SFMO anode under the cell operating conditions. 
     The cross-sectional view of the cell with Ni modified SFMO (Ni-SFMO) anode after the electrochemical testing is presented in  FIG. 2 . As shown in  FIG. 2   a , the cell consists of a 300 μm thick LSGM electrolyte, a 60 μm thick Ni-SFMO anode and a 30 μm thick LSCF cathode. Since 10 wt % pore performer was initially added to the SFMO anode ink, some large pores can be observed in the anode structure as shown in  FIG. 2   b . Figure  2   c  shows the backscattered electron (BSE) image of the Ni-SFMO anode. As the atomic number of Ni is lower than the average atomic number of SFMO, the image of Ni particles should be darker. Besides the homogeneous SFMO particles, no obvious Ni-enriched zone can be observed in  FIG. 2   c . This is likely due to the low loading and high dispersion of Ni catalyst. According to the EDS element analysis shown in  FIG. 2   d , there is only about 2 wt % Ni in the anode. 
     The performance of the fuel cells with either Ni-SFMO anode or SFMO anode at 800° C. is shown in  FIG. 3 . It can be seen that introduction of small amount of Ni phase in the SFMO anode has significantly enhanced the cell performance in both H 2  and CH 4 . With the ambient air as the oxidant, the peak power density of the fuel cells with SFMO as anode is 0.291 W cm −2  in wet H 2  (3 vol % H 2 O) and only 0.033 W cm −2  in wet CH 4  (3 vol % H 2 O) at 800° C. It is noticed that the OCV of the cell drops to 0.68V with wet CH 4  (3 vol % H 2 O) as the fuel, indicating the low catalytic activity of the SFMO material to CH 4 . With the same testing conditions, the peak power density of fuel cells with Ni-SFMO as the anode reaches 1.134 W cm −2  in wet H 2  (3 vol % H 2 O) and 0.663 W cm −2  in wet CH 4  (3 vol % H 2 O). The OCV of the cells with the Ni-SFMO anode in wet CH 4  is 0.98 V, suggesting that the catalytic activity of the SFMO anode is greatly improved by loading a small amount of Ni catalyst in the SFMO phase. The performance of cells with the Ni-SFMO anode in H 2  and CH 4  is much higher than those of fuel cells with the ceramic anodes ever reported (e.g. the highest reported peak power density of cells is 0.735 W cm −2  in H 2  with the Sr 2 CoMoO 6  anode and 0.55 W cm −2  in wet CH 4  (3 vol % H 2 O) with the Sr 1.2 La 0.8 MgMoO 6  anode at 800° C.). High performance of the Ni—SFMO anode is likely due to not only the catalytic activity of the highly dispersed Ni particles, but also the high electrical conductivity and good electrochemical activity of the SFMO ceramics. 
     The performance stability of cells with the Ni-SFMO anode in CH 4  was investigated by recording the current density of the cell operating at 0.7V at 800° C. As shown in  FIG. 4   a , the cell performance is very stable in the tested period, indicating that Ni-SFMO anode has excellent catalytic activity and stability when directly operating on CH 4  fuel. The stability of the cell is further confirmed by the impedance spectra of the cells measured under open circuit conditions in CH 4  before and after the performance stability test. Very similar impedance spectra are obtained, indicating that Ni modified SFMO anode has good stability and no significant carbon deposition occurred upon operating the cell directly with CH 4  fuel. This result would be attributed to the enlarged reaction sites on the SFMO oxide and the high dispersion of fine Ni particles which may accelerate the anode electrochemical reactions and suppress carbon formation on the confined Ni surfaces. 
     By dispersing a small amount of Ni (˜2 wt %) on the SFMO ceramic anode, performance of the cells with LSGM as electrolyte and LSCF as cathode has been dramatically improved both in H 2  and CH 4  as the fuel and ambient air as the oxidant. The improvement may be due to the high catalytic activity of Ni in electrochemical oxidation of H 2  and CH 4 . The cell performance has also been very stable when operating with CH 4  fuel, indicating that the carbon formation on Ni surface can be suppressed by controlling the dispersion and loading of Ni on the SFMO anodes. Considering the simple anode fabrication process, the relatively low cost of the anode materials and the stable cell performance observed, Ni modified SFMO anode can be considered as a promising anode system for direct-methane solid oxide fuel cells. 
     In the interest of brevity and conciseness, any ranges of values set forth in this specification are to be construed as written description support for claims reciting any sub-ranges having endpoints which are whole number values within the specified range in question. By way of a hypothetical illustrative example, a disclosure in this specification of a range of 1-5 shall be considered to support claims to any of the following sub-ranges: 1-4; 1-3; 1-2; 2-5; 2-4; 2-3; 3-5; 3-4; and 4-5. 
     These and other modifications and variations to the present disclosure can be practiced by those of ordinary skill in the art, without departing from the spirit and scope of the present disclosure, which is more particularly set forth in the appended claims. In addition, it should be understood that aspects of the various embodiments can be interchanged both in whole or in part. Furthermore, those of ordinary skill in the art will appreciate that the foregoing description is by way of example only, and is not intended to limit the disclosure so as further described in such appended claims.