Development of a high-performance composite cathode for LT-SOFC

Solid Oxide Fuel Cell (SOFC) has drawn considerable attention for decades due to its high efficiency and low pollution, which is made possible since chemical energy is directly converted to electrical energy through the system without combustion. However, successful commercialization of SOFC has been delayed due to its high production cost mainly related with using high cost of interconnecting materials and the other structural components required for high temperature operation. This is the reason that intermediate (IT) or low temperature (LT)-SOFC operating at 600~800°C or 650°C and below, respectively, is of particular significance because it allows the wider selection of cheaper materials such as stainless steel for interconnects and the other structural components. Also, extended lifetime and system reliability are expected due to less thermal stress through the system with reduced temperature. More rapid start-up/shut-down procedure is another advantage of lowering the operating temperatures. As a result, commercialization of SOFC will be more viable.;However, there exists performance drop with reduced operating temperature due to increased polarization resistances from the electrode electrochemical reactions and decreased electrolyte conductivity. Since ohmic polarization of the electrolyte can be significantly reduced with state-of-the art thin film technology and cathode polarization has more drastic effect on total SOFC electrochemical performance than anode polarization as temperature decreases, development of the cathode with high performance operating at IT or LT range is thus essential.;On the other hand, chemical stability of the cathode and its chemical compatibility with the electrolyte should also be considered for cathode development since instability and incompatibility of the cathode will also cause substantial performance loss.;Based on requirements of the cathode mentioned above, in this study, several chemico-physical approaches were carried out to develop a high-performance composite cathode, in particular, for LT-SOFC operating 650°C and below since stability and compatibility of the materials in interest are secured at low temperatures.;First, a nano-sized pyrochlore bismuth ruthenate (Bi2Ru 2O7 or BRO7 shortly), one of the promising cathode materials, was successfully synthesized using glycine-nitrate combustion (GNC) route. Stoichiometric Bi2Ru2O7 without any impurity phase was achieved with considerably improved processing condition, leading to the crystallite size of ~24nm in diameter. Even though the resulting powder tends to agglomerate, resulting in overall 200~400nm size range, it still showed better quality than the one prepared by solid state (SS) reaction route followed by extra milling steps such as vibro-milling and sonication for further particle size reduction. Glycine-to-nitrate (G/N) ratio was found to play a critical role in determining the reaction temperature and reaction duration, thus phase purity and particle morphology (particle size, shape, and agglomeration etc). Composite cathodes of such prepared BRO7 (GNC BRO7) combined with SS erbia-stabilized bismuth oxide, Bi1.6Er0.4O3 or ESB, showed better electrochemical performance than vibro-milled BRO7 (VM BRO7)-SS ESB. ASR values of 0.123Ocm2 at 700°C and 4.59cOm 2 at 500°C, respectively, were achieved, which follows well the trend of particle size effect on performance of composite cathodes. Additionally, the number of processing steps (thus time) was reduced by GNC route. Several issues in regard to synthesis process and characteristics of BRO7 material itself will be addressed in this dissertation.;Secondly, a unique in-situ composite cathode synthesis was successfully developed and applied for BRO7-ESB composite cathodes to improve percolation and to reduce agglomeration of each phase inside the cathode so that the effective triple phase boundary (TPB) length was extended. To disperse and stabilize ESB powder in de-ionized (DI) water, zeta potential profile of ESB powder in DI water as a function of pH was first achieved. The effect of a dispersant (ammonium citrate dibasic) on the stability of ESB powder dispersed in DI water was also investigated. Knowledge of BRO7 wet chemical synthesis from previous study was utilized for final product of in-situ BRO7-ESB composite cathodes. Such prepared composite particles were characterized and the electrochemical performance of in-situ BRO7-ESB composite cathodes was examined as well. Performance enhancement was observed so that ASR values of 0.097Ocm2 and 3.58Ocm2 were achieved at 700°C and 500°C, respectively, which were 19% and 22% improvement, respectively compared to those of conventionally mixed composite cathodes of BRO7-ESB.;Finally, a highly controlled nanostructured BRO7-ESB composite cathode was developed by infiltration of BRO7 onto ESB scaffolds to maximize the effective TPB length, to improve the connectivity of ESB phase inside the cathode for better oxygen-ion diffusion, and to minimize delamination between the electrolyte and cathode layers. ESB scaffolds were first established by adding a graphite pore-former and controlling heat treatment condition. Nano-sized BRO7 particles were successfully created on the surface of previously formed ESB scaffold by infiltration of concentrated (Bi, Ru) nitrate solution followed by the optimized heat treatment. Such prepared composite cathodes exhibited superior electrochemical performance to conventionally made BRO7-ESB composite cathodes and even better than GNC BRO7-SS ESB developed in this dissertation, e.g. 0.073Ocm2 at 700°C and 1.82Ocm2 at 500°C, respectively. This cathode system was revealed to be highly competitive among all the reported composite cathodes consisting of the same or different materials prepared by various processing techniques. It was demonstrated that the extended TPB length from continuous network of BRO7 nanoparticles and better connectivity of ESB scaffolds enabled the outstanding performance. Moreover, de-lamination of cathode from the electrolyte was prevented thanks to improved adhesion between ESB scaffolds and ESB electrolyte.;Dissociative adsorption of oxygen gas were proposed to be the dominant rate-determining process for the overall oxygen reduction reaction at low temperatures (500-600°C) whereas all of the constituting sub-reactions such as oxygen gas dissociative adsorption, oxygen ion diffusion towards TPB region, and oxygen ion incorporation were found to play roles competitively in the overall reaction at relatively high operating temperature (650-700°C) based on analysis of impedance spectra.