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At least 649 records · Page 36

Phase field modeling of microstructure evolution and concomitant effective conductivity change in solid oxide fuel cell electrodes

Microstructure evolution plays an important role in the performance degradation of SOFC electrodes. In this work, we propose a much improved phase field model to simulate the microstructure evolution in the electrodes of solid oxide fuel cell. We demonstrate that the tunability of the interfacial energy in this model has been significantly enhanced. Parameters are set to fit for the interfacial energies of a typical Ni-YSZ anode, an LSM-YSZ cathode and an artificial reference electrode, respectively. The contact angles at various triple junctions and the microstructure evolutions in two dimensions are calibrated to verify the model. As a demonstration of the capabilities of the model, three dimensional microstructure evolutions are simulated applying the model to the three different electrodes. The time evolutions of grain size and triple phase boundary density are analyzed. In addition, a recently proposed bound charge successive approximation algorithm is employed to calculate the effective conductivity of the electrodes during microstructure evolution. Furthermore, the effective conductivity of all electrodes are found to decrease during the microstructure evolution, which is attributed to the increased tortuosity and the loss of percolated volume fraction of the electrode phase.

30 DIRECT ENERGY CONVERSION↗

New Engineering Concepts to High Energy Density Li-S Batteries

Li-S batteries (LSBs) with energy densities > 500 Wh/kg @ C/5 and >1000 cycles, cycle life operating over wide temperatures has been identified to be critical for meeting the global energy demands. Progress is however, very much limited due to several major hurdles related to the following: (a) poor Li' reaction kinetics (conductivity/diffusivity) enabling full reversible S conversion to Li2S, (b) inferior electron (e) conductivity, specific capacity and cycle life due to electrolyte soluble species of polysulfides (PSs) formed with the reaction of Li ions with sulfur migrating to anode, (c) unstable solid electrolyte interphase (SEI) formation and finally, (d) dendrites that are formed on the Li metal anode severely limiting the cycle life due to polarization at the solid/liquid interfaces causing safety, inferior capacity, energy density, rate, and cycle life issues. Creation of a fully functional economical ≤$80/kWh, high energy density LSBs is vital for enabling its widespread commercial deployment and use in current and next generation electric vehicles.

25 ENERGY STORAGE↗

High Power Density, Carbon Neutral Electrical Power Generation for Air Vehicles

The synergistic integration of a Solid Oxide Fuel Cell-Combustor (SOFC-C) with a turbogenerator (TG) will provide a very high fuel-to-electricity conversion efficiency while maintaining high power-to-weight ratio during high-altitude flight. The proposed SOFC-C-TG power generation technology exceeds the REEACH technical performance targets (TPT). This unique concept addresses many of the challenges faced in all electric propulsion-based aviation. The system has high part-load efficiency (more than 65% lower heating value (LHV)) during long cruise times, load following capability, high-power capacity at high altitudes adapting to low temperatures and pressures, rapid startup time of less than 30 minutes (proven with current SOFC technology), high power density (more than 3.2 kW/kg), efficient thermal management, and a foundation for a compact, efficient electrical storage and power generation system (ESPG). The SOFC-C concept achieves the technology targets by reducing the complexity of traditional fuel cell-gas turbine hybrid systems (FC-GT). The SOFC-C does not require heat exchangers and dramatically reduces the balance of plant increasing power density and performance in efficiency. The reduction in mass through elimination of heat exchangers, external reformer, and other components dramatically decreases the overall thermal dampening of the system which enables rapid startup and load following capability. Direct control of the cathode inlet temperature of the SOFC-C enables rapid warm-up of the SOFC tubes with the ability to reach operating temperature and full power in less than 30 minutes.

03 NATURAL GAS↗

Membrane-electrode structures for molecular catalysts for use in fuel cells and other electrochemical devices

Water soluble catalysts, (M)meso-tetra(N-Methyl-4-Pyridyl)Porphinepentachloride (M=Fe, Co, Mn & Cu), have been incorporated into the polymer binder of oxygen reduction cathodes in membrane electrode assemblies used in PEM fuel cells and found to support encouragingly high current densities. The voltages achieved are low compared to commercial platinum catalysts but entirely consistent with the behavior observed in electroanalytical measurements of the homogeneous catalysts. A model of the dynamics of the electrode action has been developed and validated and this allows the MEA electrodes to be optimized for any chemistry that has been demonstrated in solution. It has been shown that improvements to the performance will come from modifications to the structure of the catalyst combined with optimization of the electrode structure and a well-founded pathway to practical non-platinum group metal catalysts exists.

30 DIRECT ENERGY CONVERSION↗

Recent developments in catalyst-related PEM fuel cell durability

Cost and durability remain the two major barriers to the widespread commercialization of polymer electrolyte membrane fuel cell (PEMFC)-based power systems, especially for the most impactful but challenging fuel cell electric vehicle (FCEV) application. Commercial FCEVs are now on the road; however, their PEMFC systems do not meet the cost targets established by the U.S. Department of Energy, primarily due to the high platinum loading needed on the cathode to achieve the requisite performance and lifetime. Furthermore, while the activities of a number of commercial Pt-based alloy cathode catalysts exceed the beginning-of-life (BOL) targets, these activities, and the overall cathode performance, degrade via a variety of mechanisms described herein. Degradation is mitigated in current FCEVs by utilizing a cathode catalyst with a lower BOL activity (e.g., much lower transition metal alloy content and larger BOL nanoparticle size), necessitating higher catalyst loadings, and through the utilization of system controls that avoid conditions known to exacerbate degradation processes, such as limiting the fuel cell stack voltage range. The design and development of active and robust materials and eliminating the need for vehicle mitigation strategies would greatly simplify the operating system, allowing for greater transient operation, avoiding large hybridization, and curtailing of fuel cell power. Although system mitigation strategies have provided the near-term pathway for FCEV commercialization, material-specific solutions are required to further reduce costs and improve operability and efficiency. Future material developments should focus on stabilization of the electrode structure and minimization of the catalyst particle susceptibility to dissolution caused by oxide formation and reduction over PEMFC cathode-relevant operating potentials plus minimization of support corrosion. Ex situ accelerated stress tests have provided insight into the processes responsible for material and performance degradation and will continue to provide useful information on the relative stability of materials and benchmarks for robust and stable materials-based solutions not requiring system mitigation strategies to achieve adequate lifetime.

25 ENERGY STORAGE↗

Method of forming a package for MEMS-based fuel cell

A MEMS-based fuel cell package and method thereof is disclosed. The fuel cell package comprises seven layers: (1) a sub-package fuel reservoir interface layer, (2) an anode manifold support layer, (3) a fuel/anode manifold and resistive heater layer, (4) a Thick Film Microporous Flow Host Structure layer containing a fuel cell, (5) an air manifold layer, (6) a cathode manifold support structure layer, and (7) a cap. Fuel cell packages with more than one fuel cell are formed by positioning stacks of these layers in series and/or parallel. The fuel cell package materials such as a molded plastic or a ceramic green tape material can be patterned, aligned and stacked to form three dimensional microfluidic channels that provide electrical feedthroughs from various layers which are bonded together and mechanically support a MEMS-based miniature fuel cell. The package incorporates resistive heating elements to control the temperature of the fuel cell stack. The package is fired to form a bond between the layers and one or more microporous flow host structures containing fuel cells are inserted within the Thick Film Microporous Flow Host Structure layer of the package.

30 DIRECT ENERGY CONVERSION↗

Operational constraints and strategies for systems to effect the sustainable, solar-driven reduction of atmospheric CO 2

The operational constraints for a 6-electron/6-proton CO 2 reduction system that operates at the concentration of CO 2 in the current atmosphere (p CO 2 = 400 ppm) have been evaluated on a variety of scale lengths that span from laboratory scale to global scale. Due to the low concentration of CO 2 in the atmosphere, limitations due to mass transport of CO 2 from the tropopause have been evaluated through five different regions, each with different characteristic length scales: the troposphere; the atmospheric boundary layer (ABL); the canopy layer; a membrane layer; and an aqueous electrolyte layer. The resulting CO 2 conductances, and associated physical transport limitations, will set the ultimate limit on the efficiency and areal requirements of a sustainable solar-driven CO 2 reduction system regardless of the activity or selectivity of catalysts for reduction of CO 2 at the molecular level. At the electrolyte/electrode interface, the steady-state limiting current density and the concomitant voltage loss associated with the CO 2 concentration overpotential in a one-dimensional solar-driven CO 2 reduction cell have been assessed quantitatively using a mathematical model that accounts for diffusion, migration and convective transport, as well as for bulk electrochemical reactions in the electrolyte. At p CO 2 = 400 ppm, the low diffusion coefficient combined with the low solubility of CO 2 in aqueous solutions constrains the steady-state limiting current density to <0.1 mA cm -2 in a typical electrochemical cell with natural convection and employing electrolytes with a range of pH values. Hence, in such a system, the CO 2 capture area must be 100- to 1000-fold larger than the solar photon collection area to enable a >10% efficient solar-driven CO 2 reduction system (based on the solar collection area). This flux limitation is consistent with estimates of oceanic CO 2 uptake fluxes that have been developed in conjunction with carbon-cycle analyses for use in coupled atmosphere/ocean general circulation models. Two strategies to improve the feasibility of obtaining efficient and sustainable CO 2 transport to a cathode surface at p CO 2 = 400 ppm are described and modeled quantitatively. The first strategy employs yet unknown catalysts, analogous to carbonic anhydrases, that dramatically accelerate the chemically enhanced CO 2 transport in the aqueous electrolyte layer by enhancing the acid–base reactions in a bicarbonate buffer system. The rapid interconversion from bicarbonate to CO 2 in the presence of such catalysts near the cathode surface would in principle yield significant increases in the steady-state limiting current density and allow for >10% solar-fuel operation at the cell level. The second strategy employs a thin-layer cell architecture to improve the diffusive transport of CO 2 by use of an ultrathin polymeric membrane electrolyte. Rapid equilibration of CO 2 at the gas/electrolyte interface, and significantly enhanced diffusive fluxes of CO 2 in electrolytes, are required to increase the steady-state limiting current density of such a system. This latter approach however only is feasible for gaseous products, because liquid products would coat the electrode and therefore thicken the hydrodynamic boundary layer and accordingly reduce the diffusive CO 2 flux to the electrode surface. Regardless of whether the limitations due to mass transport to the electrode surface are overcome on the laboratory scale, at global scales the ultimate CO 2 flux limitations will be dictated by mass transport considerations related to transport of atmospheric CO 2 to the boundary plane of the solar-driven reactor system. The transport of CO 2 across the troposphere/ABL interface, the ABL/canopy layer interface, and the canopy layer/electrolyte interface have therefore been assessed in this work, to provide upper bounds on the ultimate limits for the solar-to-fuel (STF) conversion efficiency for systems that are intended to effect the reduction of atmospheric CO 2 in a sustainable fashion at global scale.

54 ENVIRONMENTAL SCIENCES↗

Ferritic stainless steel interconnects for protonic ceramic electrochemical cell stacks: Oxidation behavior and protective coatings

Protonic ceramic fuel or electrolysis cells (PCFC/PCEC) have shown promising performance at intermediate temperatures. However, these technologies have not yet been demonstrated in a stack, hence the oxidation behavior of the metallic interconnect under relevant operating environments is unknown. In this work, ferritic stainless steels 430 SS, 441 SS, and Crofer 22 APU were investigated for their use as interconnect materials in the PCFC/PCEC stack. Specifically, the bare metal sheets were exposed to a humidified air environment in the temperature range from 450 °C to 650 °C, to simulate their application in a PCFC cathode or PCEC anode. Breakaway oxidation with rapid weight gain and Fe outward diffusion/oxidation was observed on all the selected stainless steel materials. A protective coating is deemed necessary to prevent the metallic interconnect from oxidizing. To mitigate the observed breakaway oxidation, state-of-the-art protective coatings, Y 2 O 3 , Ce 0.02 Mn 1.49 Co 1.49 O 4 , CuMn 1.8 O 4 and Ce/Co, were applied to the stainless steel sheets and their oxidation resistance was investigated. Dual atmosphere testing further validated the effectiveness of the protective coatings in realistic PCFC/PCEC environments, with a hydrogen gradient across the interconnect. Several combinations of metal and coating material were found to be viable for use as the interconnect for PCFC/PCEC stacks.

25 ENERGY STORAGE↗

Analysis of the Reactive CO 2 Surface Flux in Electrocatalytic Aqueous Flow Reactors

We study how the mass transfer of a chemical species in shear flow is suppressed by the production of a second species that partially reacts away the first species. The second species is produced at the surface with the first species as a reactant. Our work is directly motivated by electrochemical CO 2 reduction in aqueous flow reactors, where OH– molecules generated by the CO evolution reaction react away CO 2 molecules, ultimately inhibiting the mass transfer of CO 2 to the cathode surface. We derive a simple approximation of the Sherwood number, a dimensionless measure of the mass flux into the surface, as a function of the Péclet number, surface Damköhler number, and bulk Damköhler number, and we compare our approximation to numerical solutions of the governing equations. We find that in the diffusion-limited regime, the Sherwood number is well described by the classical Graetz-Lévêque result reduced by a reaction factor due to the competing bulk reaction; with the stoichiometry relevant to electrochemical CO 2 reduction, this reaction factor is 1/2. While the model problem we solve provides insight into how OH– production affects CO 2 mass transfer, experimental systems often involve more complex chemistry. We thus also show how a common buffered electrolyte, KHCO 3 , affects our results.

30 DIRECT ENERGY CONVERSION↗

A High-Performing Direct Carbon Fuel Cell with a 3D Architectured Anode Operated Below 600 °C

Direct carbon fuel cells (DCFCs) are highly efficient and sustainable power generators fueled by abundant and cheap solid carbons. However, the limited formation of triple phase boundaries (TPBs) within fuel electrode inhibits their performance even at very high temperatures. To address the challenges of low carbon oxidation activity and low carbon utilization simultaneously, a highly efficient anode with 3D solid-state textile framework has been developed to advance the performance of DCFCs at intermediate temperatures. The cells with the 3D textile anode, Gd:CeO 2 -Li/Na 2 CO 3 composite electrolyte, and Sm 0.5 Sr 0.5 CoO 3 (SSC) cathode have demonstrated excellent performance at intermediate temperatures with maximum power densities of 143, 196, and 325 mW cm -2 at 500, 550, and 600°C, respectively. At 500°C, the cells could be operated steadily at a constant polarization current density of 0.15Acm -2 at for approximately 2 hours with a carbon utilization reaching 86%. The significant improvement of the cell performance at low temperatures attributes to the high synergistic conduction of the composite electrolyte and the superior 3D anode structure which offers more paths for carbon catalytic oxidation. Our results indicate the feasibility of directly electrochemical oxidation of solid carbon at 500-600°C with a high carbon utilization and represent a promising strategy to develop 3D architectured electrodes for fuel cells and other electrochemical devices.

36 MATERIALS SCIENCE↗

PtCo Cathode Catalyst Morphological and Compositional Changes after PEM Fuel Cell Accelerated Stress Testing

Development of Pt catalysts alloyed with transition metals has led to a new class of state-of-the-art electrocatalysts for oxygen reduction at the cathode of proton exchange membrane fuel cells; however, the durability of Pt-based alloy catalysts is challenged by poor structural and chemical stability. There is a need for better understanding of the morphological and compositional changes that occur to the catalyst under fuel cell operation. In this work, we report in-depth characterization results of a Pt-Co electrocatalyst incorporated in the cathode of membrane electrode assemblies, which were evaluated before and after accelerated stress tests designed specifically to enhance catalyst degradation. Electron microscopy, spectroscopy, and 3D electron tomography analyses of the Pt-Co nanoparticle structures suggest that the small- and intermediate-sized Pt-Co particles, which are typically Pt-rich in the fresh condition, undergo minimal morphological changes, whereas intermediate- and larger-sized Pt-Co nanoparticles that exhibit a porous “spongy” morphology and initially have a higher Co content, transform into hollowed-out shells, which is driven by continuous leaching of Co from the Pt-Co catalysts. We further show how these primary Pt-Co nanoparticle morphologies group toward a lower Co, larger size portion of the size vs. composition distribution, and provide details of their nanoscale morphological features.

30 DIRECT ENERGY CONVERSION↗

Pore-Scale Transport Effects in Electrochemical CO 2 Reduction on Gold via Coupled Microkinetic-Transport Modeling

A pore-resolved modeling framework is developed to quantify how pore-scale transport affects the intrinsic microkinetics of CO 2 -to-CO on Au. A DFT-informed microkinetic model is coupled self-consistently to a Generalized-Modified Poisson–Nernst–Planck (GMPNP) transport description in a single, electrolyte-filled cylindrical pore, allowing local concentrations and potential to feed back into site-specific reaction rates. FIB-SEM is used to determine pore sizes within realistic electrode materials. Across pore diameters, d p = 10–6000 nm, the surface-averaged CO 2 reduction rate is systematically reduced relative to the ideal microkinetic baseline where mass transport is not accounted for; the effectiveness factor 𝜂 𝑠,CO 2 , which quantifies this ratio, decreases rapidly at more negative potentials and is about 1% near −1.0 V vs SHE due to reactant depletion. Spatial maps reveal pore-bulk alkalization that emerges at higher cathodic bias, with a small, near-wall pH dip due to electrostatic repulsion of hydroxide at the cathode interface. For a fixed aspect ratio L p /d p , narrower pores exhibit larger 𝜂 𝑠,CO 2 by shortening diffusion paths, whereas variations in the aspect ratio L p /d p play a secondary role. A dimensionless analysis (surface/bulk Damköhler numbers) delineates operating regimes. In conclusion, this work offers a concept for incorporating microkinetic models into homogenized porous-electrode models through effectiveness factors and pore-size distribution.

Au-catalyst↗

A Hybrid Catalyst-Bonded Membrane Device for Electrochemical Carbon Monoxide Reduction at Different Relative Humidities

A hybrid catalyst-bonded membrane device using gaseous reactants for a carbon monoxide reduction (COR) reaction in the cathode chamber, an aqueous electrolyte for an oxygen evolution reaction (OER) in the anode chamber, and an anion exchange membrane (AEM) for product separation as modeled, constructed, and tested. The Cu electrocatalyst was electrodeposited onto gas diffusion layers (GDLs) and was directly bonded to AEM by mechanical pressing in the hybrid device. The impacts of relative humidity at the cathode inlet on the selectivity and activity of COR were investigated by computational modeling and experimental methods. At a relative humidity of 30%, the Cu-based catalyst in the hybrid device exhibited a total operating current density of 87 mA cm -2 with a -2.0 V vs Ag/AgCl reference electrode, a Faradaic efficiency (FE) for C 2 H 4 generation of 32.6%, and an FE for a liquid-based carbon product of 42.6%. Significant improvements in the partial current densities for COR were observed in relation to planar electrodes or flooded gas diffusion electrodes (GDEs). Finally in addition, a custom test bed was constructed to characterize the oxidation states of the Cu catalysts in real time along with product analysis though the backside of the GDLs via operando X-ray absorption (XAS) measurements.

30 DIRECT ENERGY CONVERSION↗

Bipolar Membranes for Ion Management in (Photo)Electrochemical Energy Conversion

Conspectus (Photo)electrochemical energy conversion is important in the development of a carbon-neutral energy economy because it can provide a pathway for mitigating the intermittency of renewable energy sources such as wind and solar. In order to operate efficiently, these technologies, which include photoelectrochemical cells, water and CO 2 electrolyzers, fuel cells, and redox flow batteries, require fast charge transfer kinetics at the electrode/electrolyte interface as well as robust ion management in the electrolyte. In conventional electrolyzers and fuel cells, the electrolyte is strongly acidic or basic and ionic current is carried by H + or OH – ions. In contrast, photoelectrodes and electrocatalysts for water splitting are often studied in buffered solutions. The question of ion balance in these systems led us to analyze the polarization losses due to ion concentration gradients in cells that employed various buffer–membrane combinations. Continuously driving the buffer ions across an ionomer membrane not only lowers the buffer capacity of an aqueous electrolyte but also introduces pH gradients that result in significant energy losses. To address the problem, we and other groups have studied the use of reverse-biased bipolar membranes (BPMs) in (photo)electrolytic cells. BPMs consist of an anion exchange layer (AEL) laminated with a cation exchange layer (CEL) and are usually equipped with a catalytic layer in between to accelerate the water dissociation reaction. At the AEL/CEL interface, water dissociates into protons and hydroxide ions, which replenish those consumed at the cathode and anode. Compared to conventional water electrolyzers with proton/anion exchange membranes (PEM/AEM), BPM electrolyzers provide the unique advantage of continuously operating the cathode and anode under different pH conditions, which is desirable when the two electrode reactions have different pH requirements. BPMs also enable the use of buffered electrolytes at pH values that are optimized for electrode stability and product selectivity in applications such as CO 2 electrolysis. Product crossover losses and CO 2 pumping can be dramatically reduced in BPM-based CO 2 electrolyzers, relative to conventional alkaline membranes, by electrostatic repulsion (of anionic products) and electroosmotic drag (for neutral products). BPM-based gas fed CO 2 electrolyzers can achieve high current density, but they suffer from low Faradaic efficiency (FE) due to the acidic local environment of the CEL. This problem can be mitigated by adding an aqueous buffering layer or by creating a weak acid cation exchange film on the CEL face of the membrane. The use of BPMs in fuel cells and redox flow batteries offers some interesting advantages. Configurations with both reverse and forward bias have been studied, but forward bias has been favored due to material compatibility, reaction kinetics, and thermodynamic considerations. The net reaction at the AEL/CEL interface is the acid–base neutralization reaction, which has a high inherent reaction rate constant, but in the BPM is limited to a nanometric space-charge layer and requires efficient catalysis to achieve high current density. Understanding the mechanism of the acid–base neutralization and the opposite process, the water dissociation reaction, will be essential for improving the performance of forward-biased BPMs. In conclusion, this Account reviews our current understanding of the working mechanisms of BPMs and discusses how we can use them to effectively manage ions for various (photo)electrochemical applications.

Yan, Zhifei↗

Developing Accelerated Test Protocols and Tuning Microstructures of the Common Materials to Improve Robustness, Reliability, and Endurance of SOFC Cells

This work is built on our prior work where we found that phase transformation in praseodymium nickelates, e.g. Pr 2 NiO 4 (PNO) and (Pr 1-x Nd x ) 2 NiO 4 (PNNO), can be electrochemically driven, and is substantially faster when compared to thermal annealing studies. The first task aims at an attempt to further accelerate the phase transformation in the oxygen electrode by alternating the current input in the cells, which lead to the development of accelerated test protocols (ATPs). ATPs showed up to 60x faster phase transformation and up to 10x faster performance degradation in (Pr 0.50 Nd 0.50 ) 2 NiO 4 electrodes, when compared to long-term operation under constant current density. Furthermore, the phase stable Nd 2 NiO 4 and (La 0.6 Sr 0.4 )(Co 0.8 Fe 0.2 )O 3 (LSCF6482) electrodes were tested in full cells under ATPs, and showed up to 10x faster performance degradation within 1,100 hours in a comparison with long-term thermal annealing studies and electrochemical operation under constant current density. The second task aims at the quantification of the contributions of cell components to the total impedance of a solid oxide fuel cell (SOFC) using electrochemical impedance spectroscopy (EIS) and distribution of relaxation times (DRT). Specifically, the role of gas composition at both anode and cathode was systematically studied, aiming at deconvoluting, identifying and quantifying the contributions of different electrode processes. This was achieved by first tuning the partial pressure of H 2 at the anode and subsequently varying the partial pressure of O 2 at the cathode. The results suggest that, while DRT offers a viable way of deconvoluting different times distributions, additional attention is needed before assigning a peak to a specific electrode process due to the significant overlap of the contributions from the cathode and the anode. Density function theory studies show that both Pr-vacancies and O-defects play a key role on the activity and stability for nickelates towards oxygen reduction reaction. The resident O-interstitials and oxygen ions in the PrO layer form peroxide (O 2 2- ) nearby Pr vacancies. The O 2 2- limits oxygen-ion transport due to the required additional energy to break its O-O bond. We further calculated the formation and segregation energies for different Ln ions (La, Pr, Nd, Pm, Sm, Gd, Tb, Dy, and Ho) in PNO and CeO 2 (111) surfaces. In addition to Nd, Pm and La are suggested as potential dopants in PNO to enhance it stability without decomposition due to their more negative formation energies, lower diffusion energies, and positive separation energies.

01 COAL, LIGNITE, AND PEAT↗