Direct hydrocarbon metal supported solid oxide fuel cell

Patent metadata

Field	Value
Publication number	US-11322766-B2
Application number	US-202016886526-A
Country	US
Kind code	B2
Filing date	May 28, 2020
Priority date	May 28, 2020
Publication date	May 3, 2022
Grant date	May 3, 2022

Abstract

A solid oxide fuel cell including a hydrocarbon reforming catalyst and a method for forming the solid oxide fuel cell are provided. An exemplary solid oxide fuel cell includes a cell. The cell includes a filled metal substrate including holes substantially filled with a permeable material that includes a hydrocarbon reforming catalyst, wherein the filled metal substrate has a front facing a fuel flow and a back facing an electrochemical stack. A permeable layer is formed on the back of the filled metal substrate that is in contact with the permeable material of the filled holes. The cell includes an anode layer proximate to the permeable layer, an electrolyte layer proximate to the anode layer, a diffusion barrier proximate to the anode layer, and a cathode proximate to the diffusion barrier.

First claim

What is claimed is:

1. A solid oxide fuel cell (SOFC), comprising a cell comprising:
a filled metal substrate comprising holes substantially filled with a permeable material that comprises a hydrocarbon reforming catalyst, wherein the filled metal substrate has a front facing a fuel flow, and a back facing an electrochemical stack;
a permeable layer formed on the back of the filled metal substrate that is in contact with the permeable material of the filled holes, wherein the permeable material comprises an inorganic binder;
an anode layer proximate to the permeable layer;
an electrolyte layer proximate to the anode layer;
a diffusion barrier proximate to the anode layer; and
a cathode proximate to the diffusion barrier.

2. The SOFC of claim 1 , wherein the filled metal substrate is between about 150 μm and about 300 μm in thickness.

3. The SOFC of claim 1 , wherein the filled metal substrate is about 200 μm in thickness.

4. The SOFC of claim 1 , wherein the permeable layer is between about 30 μm and about 70 μm in thickness.

5. The SOFC of claim 1 , wherein the permeable layer is about 40 μm in thickness.

6. The SOFC of claim 1 , wherein the anode layer is between about 30 μm and about 70 μm in thickness.

7. The SOFC of claim 1 , wherein the anode layer is about 40 μm in thickness.

8. The SOFC of claim 1 , wherein the electrolyte layer is between about 1.5 μm and 3 μm in thickness.

9. The SOFC of claim 1 , wherein the electrolyte layer is about 2 μm in thickness.

10. The SOFC of claim 1 , wherein the diffusion barrier is between about 100 nm and about 500 nm in thickness.

11. The SOFC of claim 1 , where the diffusion barrier is about 350 nm in thickness.

12. The SOFC of claim 1 , wherein the hydrocarbon reforming catalyst comprises nickel, Ni—Ru/CGO (gadolinium doped ceria), Ni/CGO, Ru/CGO, or Ni—Ce 2 O 3 —Pt—Rh, or any combinations thereof.

13. The SOFC of claim 1 , wherein the hydrocarbon reforming catalyst comprises Ni—Ru/CGO.

14. The SOFC of claim 1 , wherein the permeable layer comprises the hydrocarbon reforming catalyst.

15. The SOFC of claim 1 , wherein the permeable layer comprises an interconnect coating material.

16. The SOFC of claim 15 , where the interconnect coating material comprises Y 0.2 Sr 0.8 TiO 3 , La 0.3 Sr 0.7 TiO 3 , or MnCo 3 O 4 , or any combinations thereof.

17. The SOFC of claim 1 , wherein an interconnect coating material is coated on the front of the filled metal substrate.

18. The SOFC of claim 1 , wherein the anode layer comprises LST (La 0.3 Sr 0.7 TiO 3 ) and CGO (gadolinium doped ceria).

19. The SOFC of claim 1 , wherein the electrolyte layer comprises a mixture of CGO and yttria-stabilized zirconia (YSZ).

20. The SOFC of claim 1 , wherein the diffusion barrier comprises CGO.

21. The SOFC of claim 1 , wherein the cathode comprises a blend of LSCF (lanthanum strontium cobalt ferrite) and CGO.

22. A solid oxide fuel cell (SOFC), comprising a cell comprising:
a filled metal substrate comprising holes substantially filled with a permeable material that comprises a hydrocarbon reforming catalyst, wherein the filled metal substrate has a front facing a fuel flow, and a back facing an electrochemical stack;
a permeable layer formed on the back of the filled metal substrate that is in contact with the permeable material of the filled holes, wherein the permeable layer comprises an interconnect coating material, and where the interconnect coating material comprises Y 0.2 Sr 0.8 TiO 3 , La 0.3 Sr 0.7 TiO 3 , or MnCo 3 O 4 , or any combinations thereof;
an anode layer proximate to the permeable layer;
an electrolyte layer proximate to the anode layer;
a diffusion barrier proximate to the anode layer; and
a cathode proximate to the diffusion barrier.

23. The SOFC of claim 22 , wherein the hydrocarbon reforming catalyst comprises Ni—Ru/CGO.

24. The SOFC of claim 22 , wherein the permeable layer comprises the hydrocarbon reforming catalyst.

25. A solid oxide fuel cell (SOFC), comprising a cell comprising:
a filled metal substrate comprising holes substantially filled with a permeable material that comprises a hydrocarbon reforming catalyst, wherein the filled metal substrate has a front facing a fuel flow, and a back facing an electrochemical stack;
a permeable layer formed on the back of the filled metal substrate that is in contact with the permeable material of the filled holes;
an anode layer proximate to the permeable layer, wherein the anode layer comprises LST (La 0.3 Sr 0.7 TiO 3 ) and CGO (gadolinium doped ceria);
an electrolyte layer proximate to the anode layer;
a diffusion barrier proximate to the anode layer; and
a cathode proximate to the diffusion barrier.

26. The SOFC of claim 25 , wherein the hydrocarbon reforming catalyst comprises Ni—Ru/CGO.

27. The SOFC of claim 25 , wherein the permeable layer comprises the hydrocarbon reforming catalyst.

Assignees

• Saudi Arabian Oil Co

Inventors

• Lee Kunho
• Katikaneni Sai P

Classifications

• Y02E60/50

  Fuel cells · CPC title

• Y02P70/50

  Manufacturing or production processes characterised by the final manufactured product · CPC title

• H01M8/126

  the electrolyte containing cerium oxide · CPC title

• H01M4/8846

  Impregnation · CPC title

• H01M4/8657

  layered · CPC title