CA2534590A1 - Stack supported solid oxide fuel cell - Google Patents

Stack supported solid oxide fuel cell Download PDF

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Publication number
CA2534590A1
CA2534590A1 CA002534590A CA2534590A CA2534590A1 CA 2534590 A1 CA2534590 A1 CA 2534590A1 CA 002534590 A CA002534590 A CA 002534590A CA 2534590 A CA2534590 A CA 2534590A CA 2534590 A1 CA2534590 A1 CA 2534590A1
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CA
Canada
Prior art keywords
solid oxide
oxide fuel
fuel cell
cell stack
layer
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Granted
Application number
CA002534590A
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French (fr)
Other versions
CA2534590C (en
Inventor
Oh-Hun Kwon
William J. Donahue
Marc Abouaf
Christophe Coureau
F. Michael Mahoney
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Saint Gobain Ceramics and Plastics Inc
Original Assignee
Saint-Gobain Ceramics & Plastics, Inc.
Oh-Hun Kwon
William J. Donahue
Marc Abouaf
Christophe Coureau
F. Michael Mahoney
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Application filed by Saint-Gobain Ceramics & Plastics, Inc., Oh-Hun Kwon, William J. Donahue, Marc Abouaf, Christophe Coureau, F. Michael Mahoney filed Critical Saint-Gobain Ceramics & Plastics, Inc.
Publication of CA2534590A1 publication Critical patent/CA2534590A1/en
Application granted granted Critical
Publication of CA2534590C publication Critical patent/CA2534590C/en
Expired - Fee Related legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M8/00—Fuel cells; Manufacture thereof
    • H01M8/02—Details
    • H01M8/0202—Collectors; Separators, e.g. bipolar separators; Interconnectors
    • H01M8/023—Porous and characterised by the material
    • H01M8/0232—Metals or alloys
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M8/00—Fuel cells; Manufacture thereof
    • H01M8/10—Fuel cells with solid electrolytes
    • H01M8/12—Fuel cells with solid electrolytes operating at high temperature, e.g. with stabilised ZrO2 electrolyte
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/86—Inert electrodes with catalytic activity, e.g. for fuel cells
    • H01M4/8605—Porous electrodes
    • H01M4/8621—Porous electrodes containing only metallic or ceramic material, e.g. made by sintering or sputtering
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/86—Inert electrodes with catalytic activity, e.g. for fuel cells
    • H01M4/88—Processes of manufacture
    • H01M4/8878—Treatment steps after deposition of the catalytic active composition or after shaping of the electrode being free-standing body
    • H01M4/8882—Heat treatment, e.g. drying, baking
    • H01M4/8885—Sintering or firing
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/86—Inert electrodes with catalytic activity, e.g. for fuel cells
    • H01M4/90—Selection of catalytic material
    • H01M4/9016—Oxides, hydroxides or oxygenated metallic salts
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/86—Inert electrodes with catalytic activity, e.g. for fuel cells
    • H01M4/90—Selection of catalytic material
    • H01M4/9016—Oxides, hydroxides or oxygenated metallic salts
    • H01M4/9025—Oxides specially used in fuel cell operating at high temperature, e.g. SOFC
    • H01M4/9033—Complex oxides, optionally doped, of the type M1MeO3, M1 being an alkaline earth metal or a rare earth, Me being a metal, e.g. perovskites
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/86—Inert electrodes with catalytic activity, e.g. for fuel cells
    • H01M4/90—Selection of catalytic material
    • H01M4/9041—Metals or alloys
    • H01M4/905—Metals or alloys specially used in fuel cell operating at high temperature, e.g. SOFC
    • H01M4/9066—Metals or alloys specially used in fuel cell operating at high temperature, e.g. SOFC of metal-ceramic composites or mixtures, e.g. cermets
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M8/00—Fuel cells; Manufacture thereof
    • H01M8/02—Details
    • H01M8/0202—Collectors; Separators, e.g. bipolar separators; Interconnectors
    • H01M8/0204—Non-porous and characterised by the material
    • H01M8/0223—Composites
    • H01M8/0226—Composites in the form of mixtures
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M8/00—Fuel cells; Manufacture thereof
    • H01M8/02—Details
    • H01M8/0202—Collectors; Separators, e.g. bipolar separators; Interconnectors
    • H01M8/023—Porous and characterised by the material
    • H01M8/0236—Glass; Ceramics; Cermets
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M8/00—Fuel cells; Manufacture thereof
    • H01M8/10—Fuel cells with solid electrolytes
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M8/00—Fuel cells; Manufacture thereof
    • H01M8/10—Fuel cells with solid electrolytes
    • H01M8/12—Fuel cells with solid electrolytes operating at high temperature, e.g. with stabilised ZrO2 electrolyte
    • H01M8/1231—Fuel cells with solid electrolytes operating at high temperature, e.g. with stabilised ZrO2 electrolyte with both reactants being gaseous or vaporised
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M8/00—Fuel cells; Manufacture thereof
    • H01M8/10—Fuel cells with solid electrolytes
    • H01M8/12—Fuel cells with solid electrolytes operating at high temperature, e.g. with stabilised ZrO2 electrolyte
    • H01M8/124—Fuel cells with solid electrolytes operating at high temperature, e.g. with stabilised ZrO2 electrolyte characterised by the process of manufacturing or by the material of the electrolyte
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M8/00—Fuel cells; Manufacture thereof
    • H01M8/24—Grouping of fuel cells, e.g. stacking of fuel cells
    • H01M8/241—Grouping of fuel cells, e.g. stacking of fuel cells with solid or matrix-supported electrolytes
    • H01M8/2425—High-temperature cells with solid electrolytes
    • H01M8/2432—Grouping of unit cells of planar configuration
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/30—Hydrogen technology
    • Y02E60/50—Fuel cells
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
    • Y02P70/50—Manufacturing or production processes characterised by the final manufactured product

Abstract

The disclosure is directed to a solid oxide fuel cell stack. The solid oxide fuel cell stack includes at least two solid oxide fuel cells. The two solid oxide fuel cells share a common electrode.

Claims (60)

1. A solid oxide fuel cell stack, comprising:
a first electrode layer;
a first electrolyte layer overlying the first electrode layer;
a common electrode layer overlying the first electrolyte layer;
a second electrolyte layer overlying the common electrode layer; and a second electrode layer overlying the second electrolyte layer, wherein the first and second electrode layers are an anode or cathode, and the common electrode layer is the other of the anode or cathode, and wherein the first electrode layer, the first electrolyte layer and the common electrode form a first solid oxide fuel cell, and the common electrode, the second electrolyte layer and the second electrode layer form a second solid oxide fuel cell.
2. The solid oxide fuel cell stack of claim 1, wherein the common electrode layer is a cathode and the first and second electrode layers are anodes.
3. The solid oxide fuel cell stack of claim 1, wherein the common electrode layer is an anode and the first and second electrode layers are cathodes.
4. The solid oxide fuel cell stack of claim 1, wherein the solid oxide fuel cell stack further comprises a third solid oxide fuel cell sharing the second electrode layer with the second solid oxide fuel cell.
5. The solid oxide fuel cell stack of claim 1, wherein the common electrode layer comprises channels.
6. The solid oxide fuel cell stack of claim 5, wherein the first and second electrode layers include channels.
7. The solid oxide fuel cell stack of claim 5, wherein the channels have a characteristic diameter of between 0.1mm and 5 mm.
8. The solid oxide fuel cell stack of claim 5, wherein the channels are formed by a subtractive process.
9. The solid oxide fuel cell stack of claim 5, wherein the channels are formed by oxidation of a channel former wherein the channel former comprises carbon.
10. The solid oxide fuel cell stank of claim 9, wherein the channel former is amorphous carbon, carbon black, graphite, or graphite-resin composite.
11. The solid oxide fuel cell stack of claim 5, wherein the channels are formed by a non-subtractive process.
12. The solid oxide fuel cell stack of claim 11, wherein the channels are molded in place.
13. The solid oxide fuel cell stack of claim 1, further comprising a current collector.
14. The solid oxide fuel cell stack of claim 13, wherein the current collector is embedded in the common electrode layer.
15. The solid oxide fuel cell stack of claim 14, wherein current collectors are embedded in the common electrode layer, the first electrode layer and the second electrode layer.
16. The solid oxide fuel cell stack of claim 13, wherein the current collector comprises nickel.
17. The solid oxide fuel cell stack of claim 1, wherein the stack is free of a gas impermeable interconnect.
18. The solid oxide fuel cell stack of claim 1, further comprising electrical contacts coupled to an outer edge of each of the first, second and common electrode layers.
19. The solid oxide fuel cell stack of claim 1, wherein the stack is joined by hot pressing.
20. The solid oxide fuel cell stack of claim 19, wherein hot pressing includes a hot press cycle having a cycle period of not greater than 60 minutes.
21. The solid oxide fuel cell stack of claim 1, wherein the common electrode layer has a porous structure formed by a subtractive process.
22. The solid oxide fuel cell stack of claim 21, wherein the common electrode layer has a porous structure formed by oxidation of a pore former.
23. The solid oxide fuel cell stack of claim 22, wherein the pore former comprises carbon.
24. The solid oxide fuel cell stack of claim 23, wherein the pore former is carbon black or amorphous carbon.
25. The solid oxide fuel cell stack of claim 1, wherein a cell thickness of at least one of the first and second solid oxide fuel cells is not greater than 10 mm.
26. The solid oxide fuel cell stack of claim 1, wherein a cell thickness of at least one of the first and second solid oxide fuel cells is not greater than 5 mm.
27. The solid oxide fuel cell stack of claim 1, wherein a cell thickness of at least one of the first and second solid oxide fuel cells is not greater than 3 mm.
28. The solid oxide fuel cell stack of claim 1, wherein an electrolyte thickness of at least one of the first and second electrolyte layers is not greater than 100 micrometers and an electrode thickness of the common electrode is not greater than 5 mm.
29. The solid oxide fuel cell stack of claim 1, wherein the first and second electrolyte layers comprise a material selected from the group consisting of zirconia, ceria, and gallia.
30. The solid oxide fuel cell stack of claim 29, wherein the material is stabilized with a stabilizing material selected from the group consisting of scandium, samarium, gadolinium, and yttrium.
31. The solid oxide fuel cell stack of claim 30, wherein the material comprises yttria stabilized zirconia.
32. The solid oxide fuel cell stack of claim 1, wherein the common electrode layer or the first and second electrode layers form an anode, the anode comprising nickel and yttria stabilized zirconia.
33. The solid oxide fuel cell stack of claim 32, wherein the anode is formed by reduction of a green body comprising nickel oxide and yttria stabilized zirconia.
34. The solid oxide fuel cell stack of claim 1, wherein the common electrode layer or the first and second electrode layers form an anode, the anode comprising nickel and gadolinium stabilized ceria.
35. The solid oxide fuel cell stack of claim 34, wherein the anode is formed by reduction of a green body comprising nickel oxide and gadolinium stabilized ceria.
36. The solid oxide fuel cell stack of claim 1, wherein the common electrode layer or the first and second electrode layers form a cathode, the cathode comprising a material selected from the group consisting of lanthanum strontium manganite, lanthanum strontium ferrite, and lanthanum strontium cobalt ferrite.
37. The solid oxide fuel cell stack of claim 36, wherein the cathode comprises lanthanum strontium manganite.
38. An integrated solid oxide fuel cell stack comprising:

a first anode layer;
a first electrolyte layer overlying the first anode layer, a first cathode layer overlying the first anode layer;
a second electrolyte layer overlying the first cathode layer; and a second anode layer overlying the second electrolyte layer.
39. The solid oxide fuel cell stack of claim 38, further comprising:
a third electrolyte overlying the second anode; and a second cathode layer overlying the third electrolyte.
40. The solid oxide fuel cell stack of claim 38, further comprising a current collector.
41. The solid oxide fuel cell stack of claim 40, wherein the current collector is embedded in the first anode.
42. The solid oxide fuel cell stack of claim 40, wherein the current collector comprises nickel.
43. The solid oxide fuel cell stack of claim 38, further comprising a current collector integrated with the first cathode layer.
44. The solid oxide fuel cell stack of claim 38, further comprising:
channels in the first and second anodes.
45. The solid oxide fuel cell stack of claim 38, further comprising:
channels in the first cathode.
46. A solid oxide fuel cell system comprising:
a fuel system for conditioning fuel;
an air system for conditioning air;
a solid oxide fuel cell stack connected to the fuel system and connected to the air system, the solid oxide fuel cell stack having a first electrode layer; a first electrolyte layer overlying the first electrode layer; a common electrode layer overlying the first electrolyte layer; a second electrolyte layer overlying the common electrode layer; and a second electrode layer overlying the second electrolyte layer, wherein the first and second electrode layers are an anode or cathode, and the common electrode layer is the other of the anode or cathode; and a power conditioner electrically coupled to the solid oxide fuel cell stack.
47. The solid oxide fuel cell system of claim 46, wherein the fuel system is in fluid communication with an anode of the solid oxide fuel cell stack and wherein the air system is in fluid communication with a cathode of the solid oxide fuel cell stack.
48. A solid oxide fuel cell system comprising:
a fuel system for conditioning fuel;
an air system for conditioning air;
a solid oxide fuel cell stack connected to the fuel system and connected to the air system, the solid oxide fuel cell stack having:
a first anode layer, a first electrolyte layer overlying the first anode layer;
a first cathode layer overlying the first anode layer;
a second electrolyte layer overlying the first cathode layer; and a second anode layer overlying the second electrolyte layer.; and a power conditioner electrically coupled to the solid oxide fuel cell stack.
49. The solid oxide fuel cell system of claim 48, wherein the fuel system is in fluid communication with the first anode layer and the second anode layer and wherein the air system is in fluid communication with the first cathode layer.
50. A method of forming a solid oxide fuel cell, the method comprising:
forming a solid oxide fuel cell including a cathode layer, a anode layer, and an electrolyte layer provided between the anode layer and the cathode layer; and densifying the solid oxide fuel cell in an oxidizing environment.
51. The method of claim 50, wherein densifying is carried out by pressure-sintering.
52. The method of claim 51, wherein pressure-sintering includes hot pressing.
53. The method of claim 51, wherein pressure-sintering includes hot forging.
54. The method of claim 50, wherein the method is carried out to form multiple solid oxide fuel cells provided in a stack, the multiple solid oxide fuel cells being densified together.
55. A solid oxide fuel cell comprising:
an anode layer comprising integrated microchannels;
an electrolyte layer overlying the anode layer; and a cathode layer comprising integrated microchannels, the cathode overlying the electrolyte layer.
56. The solid oxide fuel cell of claim 55, wherein the integrated microchannels of at least one of the cathode or the anode are formed by a subtractive process.
57. The solid oxide fuel cell of claim 55, wherein the integrated microchannels of at least one of the cathode or the anode are formed by non-subtractive process.
58. The solid oxide fuel cell of claim 55, wherein the solid oxide fuel cell is electrically connected to other solid oxide fuel cells in a parallel circuit configuration.
59. The solid oxide fuel cell of claim 55, wherein the solid oxide fuel cell is electrically connected to other solid oxide fuel cells in a series circuit configuration.
60. The solid oxide fuel cell of claim 55, wherein the solid oxide fuel cell is electrically connected to other solid oxide fuel cells in a hybrid series/parallel circuit configuration.
CA2534590A 2003-06-09 2004-06-09 Stack supported solid oxide fuel cell Expired - Fee Related CA2534590C (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US47714903P 2003-06-09 2003-06-09
US60/477,149 2003-06-09
PCT/US2004/018267 WO2005001959A2 (en) 2003-06-09 2004-06-09 Stack supported solid oxide fuel cell

Publications (2)

Publication Number Publication Date
CA2534590A1 true CA2534590A1 (en) 2005-01-06
CA2534590C CA2534590C (en) 2010-03-23

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US (1) US7550217B2 (en)
EP (1) EP1639671B1 (en)
JP (1) JP4986623B2 (en)
KR (1) KR100813089B1 (en)
CN (1) CN1802769A (en)
AU (1) AU2004252862B2 (en)
BR (1) BRPI0411230A (en)
CA (1) CA2534590C (en)
MX (1) MXPA05013582A (en)
RU (1) RU2337431C2 (en)
WO (1) WO2005001959A2 (en)

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