摘要
固体氧化物燃料电池(SOFC)是一种能够清洁、高效地将储存在各种燃料如氢气、碳氢化合物、煤气、生物质气等中的化学能转化为电能的能量转换装置。毫无疑问,SOFC作为能量供应装置的大规模应用必然能够有效缓解日益严峻的环境污染以及化石燃料的消耗。
在本论文的第一章中,我们将对SOFC的基本知识以及各主要的组分材料进行陈述。在此基础上指出,要实现SOFC技术的商业化,必须将其操作温度由传统的800～1000℃降低到700℃甚至更低,这就需要大力发展在中低温时具有更高性能的电极和电解质材料。正是基于这一点,在本论文之后的章节中,我们将分别致力于对纳米颗粒浸渍能够改善Ni基阳极性能根源的揭示(第二章),对采用甘氨酸-硝酸盐法(GNP)合成氧化钐掺杂的氧化铈(SDC)电解质粉体工艺的优化(第三章),于更低烧结温度下制备SDC电解质基单电池(第四章),以及简化的三层不锈钢支撑单电池的研制(第五章)等工作,以期能够对中低温SOFC技术的发展和商业化进程起到一定的促进作用。
已有许多研究证明向SOFC的阳极中浸渍氧化物纳米颗粒能够改善其电化学性能。不过,截至目前,人们仍不清楚这种改善究竟是源于浸渍的纳米颗粒对阳极反应活性区域(三相界面)的扩展还是对其催化活性的提高。因此,在本论文的第二章中,我们分别制备了SDC、纯二氧化铈、氧化钐和氧化铝这几种不同氧化物浸渍的Ni基阳极来对比研究这两种效应。在研究中我们发现,除A1203外,其余三种氧化物纳米颗粒的浸渍均能有效改善阳极对氢气氧化反应的催化活性。同时,具有CeO2和Sm203浸渍阳极的单电池能够表现出与通过SDC浸渍阳极的单电池差不多的输出性能,当这些氧化物颗粒的浸渍量达到最佳值～1.7mmolcm-3时,电池会表现出最高的输出性能,峰功率密度均在750mWcm-2左右。这就说明浸渍后阳极性能的提高主要是源于其电化学催化活性的显著提高,而非三相界面的扩展。同时,这些研究也再次证明湿化学浸渍法确实是一种高效的向SOFC阳极骨架中引入具有高催化活性的纳米氧化物颗粒以提高电池输出性能和稳定性的修饰工艺。
另外,由于掺杂的氧化铈材料在低温时具有比经典的氧化钇稳定的氧化锆(YSZ)电解质更高的氧离子电导率,许多研究者也致力于发展采用这种薄膜电解质的单电池,其中一种较为简便的方法便是采用共压-共烧工艺直接在多孔阳极衬底上制备致密电解质层,能够大大降低生产成本。不过对于这种制备工艺而言,最为关键的便是要合成出具有尽可能低的松装密度的电解质粉体,通常是由甘氨酸-硝酸盐法(GNP)来实现的。在本论文的第三章中,我们发现采用适当比例的Ce(NO3)3和Ce(NH4)2(NO3)6作为混合铈源能够合成出便于制备高密度高性能的电解质薄膜的具有低松装密度和高氧离子电导率的SDC粉体。其中,当这两种铈源的摩尔比为1：1时,所合成出的SDC粉体易于被烧结致密,同时能够表现出最高的的电导率(在600和800℃时分别为～0.020和～0.084Scm-1)和最低的电导活化能(-0.70eV)。而当Ce(N03)3和Ce(NH4)2(NO3)6的摩尔比为3：1时,所合成出的SDC粉体具有最低的松装密度(36.0±0.5mgcm-3),最适宜于在多孔阳极衬底上制备致密的SDC电解质薄膜,这也正是在低成本前提下制备高性能SOFC最为重要的一步。
对于SDC电解质材料而言,限制其应用的一项重要缺陷便是其烧结活性较差,很难在1500℃以下烧结得足够致密。因此,许多研究者也致力于改进SDC粉体的烧结活性,以期有效的降低其烧结温度,在优化电极微结构的同时,抑制甚至消除电池组分间的不利相互扩散和反应。在本论文的第四章中,我们采用第三章中使用75mol%Ce(NO3)3和25mol%Ce(NH4)2(NO3)6作为混合铈源所合成出的具有最低松装密度的高活性SDC粉体,借助共压-共烧工艺成功于1150℃的低温制备出了高性能的SOFC单电池。并且,由于烧结温度的降低,电池的阳极具有更合适的孔隙率和粒径,从而具有更佳的微结构以及与电解质层更优的连接性,使得电池的欧姆阻抗和极化阻抗均显著降低,大大提高电池输出性能。此外,我们还发现,当电池于650℃的高温进行工作时,其于高电流密度区域的浓差极化也会得到很好的缓解。
近些年,由于具有更好的机械强度,对急速热循环和氧化还原周期更好的抵抗力,以及更低的成本,一些金属支撑构型单电池的研制也受到越来越多的关注。通常状况下,这些金属支撑构型单电池都包括金属支撑体、阳极、电解质和阴极这四层结构。在本论文的最后一章,我们设计了一种简化的无需阳极功能层的三层结构的不锈钢支撑构型。具体的,我们先通过共烧工艺制备出YSZ电解质层与430系列不锈钢支撑体,随后将Ni和SDC颗粒浸入不锈钢支撑体中以提高其电化学氧化反应催化活性。在700℃时,我们所制备的单电池达到了～246mWcm-2的峰功率密度,并对五个周期的充分氧化还原过程表现出了良好的抗性,从而证明采用这种简化的三层结构制备高性能的金属支撑SOFC单电池是完全可行的。
Solid Oxide Fuel Cells (SOFCs) are regarded as one of the cleanest and most efficient devices for direct conversion to electricity of a wide variety of fuels, from hydrogen to hydrocarbons, coal gas, and bio-derived renewable fuels. It is believed that broad application of SOFCs for power generation alone can significantly reduce pollutant emission and consumption of fossil fuels.
In Chapter1, a brief introduction is presented on the basic concepts and the main component materials of SOFCs. Then it is concluded that for the commercialization of SOFC technologies, it is vital to lower the operation temperature from traditional800-1000℃to700℃or lower, which requires further development of both high performance electrode and electrolyte materials at reduced temperatures. Thus, in the following parts of this thesis, we will mainly focus on the revelation of the reason why nanoparticles impregnation can improve the performance of Ni based anode (Chapter2), the optimization of samaria-doped ceria (SDC) electrolyte synthesis by glycine-nitrate process (GNP)(Chapter3), the fabrication of SDC electrolyte based single cells at reduced co-firing temperature (Chapter4), as well as the design of simplified three-layer stainless steel supported single cells (Chapter5), respectively, with the goal of promoting the development and commercialization of intermediate and low temperature SOFCs.
Impregnated nanoparticles are very effective in improving the electrochemical performance of SOFC anodes possibly due to the extension of reaction sites and/or the enhancement of catalytic activity. To date, however, it remains unclear which effect plays a dominant role. Thus, in Chapter2, SDC, pure ceria, samaria, and alumina oxides impregnated Ni-based anodes are fabricated to compare the site extending and the catalytic effects. Except for alumina, the impregnation of the other three nano-sized oxides could substantially enhance the performance of the anodes for the hydrogen oxidation reactions. Moreover, single cells with CeO2and Sm2O3impregnated anodes could exhibit as great performance as those with SDC impregnated anodes. When the impregnation loading reached the optimal value,1.7mmolcm-3, these cells exhibit very high performance, with peak power densities around750mWcm-2. The high performance of CeO2and Sm2O3impregnated anodes demonstrates that the improved performance are mainly attributed to the significantly improved electrochemical activities of the anodes, but not to the extension of triple-phase-boundary, and wet impregnation is indeed an alternative and effective technique to introduce these nano-sized catalytic active oxides into the anode configuration of SOFCs to enhance cell performance, stability and reliability.
On the other hand, considerable efforts have been devoted to the development of single cells with thin-film electrolytes of doped ceria, which show much higher ionic conductivities than the state-of-the-art yttria-stabilized zirconia (YSZ) electrolytes at reduced temperatures. A simple and elegant approach to fabrication of dense electrolyte films on porous anode substrates is a co-pressing and co-firing process, significantly reducing the fabrication cost. However, the critical step is the synthesis of electrolyte powders with extremely low apparent density, usually achieved via a GNP. In Chapter3, proper combination of Ce(NO3)3and Ce(NH4)2(NO3)6as mixed cerium source is shown to be more effective in achieving SDC powders with low apparent density for easy fabrication of thin-film electrolyte membrane with very high sintered density and excellent ionic conductivity. In particular, when the molar ratio of the two cerium precursors is around1:1, the derived SDC powders can be readily sintered to high density, exhibiting the highest conductivities (～0.084and～0.020Scm-1at800and600℃, respectively) with the activation energy of～0.70eV. When the molar ratio of Ce(NO3)3to Ce(NH4)2(NO3)6was adjusted to3:1, the derived SDC powders have the lowest apparent density (36.0±0.5mgcm-3), best suited for preparation of dense, thin-film SDC electrolyte membranes on porous anode substrates, a critical step toward low-cost fabrication of high-performance SOFCs.
For SDC based electrolyte, one of the main drawbacks which may limit its utilization is its poor sinterability, making it difficult to achieve sufficiently high density below1500℃. Thus, many efforts have been devoted to improving the sinterability of SDC powders in order to effectively reduce the firing temperature, to optimize the electrode microstructure, and to minimize or eliminate unfavorable diffusion and reaction between cell components. In Chapter4, we have successfully fabricated high-performance, single cells by co-pressing followed by co-sintering at a temperature as low as1150℃using highly-active SDC powders derived from a modified GNP which uses75mol%Ce(NO3)3and25mol%Ce(NH4)2(NO3)6as a mixed cerium source as elaborated in Chapter3. In particular, the low firing temperature has resulted in anode microstructures with more appropriate porosity, grain size, and connectivity with the electrolyte, significantly reducing both the ohmic resistance and the electrode polarization resistance and enhancing cell performance. In addition, it is found that the electrode polarization at high current densities is significantly suppressed when operated at650℃.
Recently, there have been lots of interests in developing metal-supported SOFCs, driven by their excellent strength, high tolerance to extremely rapid thermal cycling and redox cycling, as well as low material cost. These metal-supported SOFCs are usually four-layer structure consisting of the metal support, the anode, the electrolyte and the cathode. In the last chapter, a simplified three-layer design without the anode interlayer is proposed. The novel design is demonstrated by co-firing YSZ electrolytes and43OL stainless steel substrates, where Ni and doped ceria are impregnated to increase the catalytic activity towards electrochemical oxidation. Peak power density as high as246mWcm-2is obtained at700℃, and good tolerance to five complete redox cycles is also initially demonstrated, suggesting that this design is feasible for high performance metal-supported SOFCs.
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