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Electrochimica Acta 45 (2000) 2423 – 2435

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Solid oxide fuel cells: fundamental aspects and prospects


Osamu Yamamoto
Aichi Institute of Technology, Yatigusa, Toyota, Aichi 470 -0392, Japan

Papers received in Newcastle, 20 December 1999

Abstract

Solid oxide fuel cells (SOFCs) are advanced electrochemical reactors operating at a high temperature. SOFCs are
presently under development for a variety of electric power generation applications with high energy conversion
efficiency. This paper reviews the science and technology of SOFCs with emphasis on discussion of their component
materials. © 2000 Elsevier Science Ltd. All rights reserved.

1. Introduction the phosphoric acid fuel cell (PAFC), the molten car-
bonate fuel cell (MCFC), and the solid oxide fuel cell
The origin of fuel cells goes back to the middle of the (SOFC) have been mainly developed. These fuel cells
last century, their principle was first described by Sir are characterized by the electrolyte used, which in turn
William Grove in 1839 [1]. His fuel cell, operating at determines the operating temperature. The characteris-
room temperature, used a dilute sulfuric acid elec- tics and the current status of different types of fuel cells
trolyte, a hydrogen anode and an oxygen cathode. At are summarized in Table 1. The most advanced fuel cell
system is the PAFC. More than 200 PAFC units have
that time no conventional batteries such as lead acid
been introduced as on-site electric power plants. How-
batteries or Leclanche type cells were yet available and
ever, a serious problem for commercialization of PAFC
so four fuel cells were connected in series and were
is their high unit cost. PEFCs have recently attracted
applied to the electrolysis of water. Thus, fuel cells
significant attention as a potential source of primary
become the first electric high power supply.
power in transportation applications. As shown in
Fuel cells are energy conversion devices that produce
Table 1, SOFCs have exceptional potential for use as
electricity directly from a gaseous fuel by electrochemi-
electric power generation systems, because of their high
cal combination of the fuel with an oxidant. Fuel cells
energy conversion efficiency which can reach up to
have many advantages compared to conventional elec-
65%. In addition, SOFCs have many advantages such
tric power generation systems, such as high conversion as multi-fuel capability and simplicity of system design
efficiency, which is relatively independent of size, as [2]. Furthermore, the exhaust heat can be used as a heat
well as environmental compatibility. The first successful source for a variety of processes. This together with the
practical applications of fuel cells was for space appli- possibility of utilizing the remaining energy in a bot-
cations in the 1960s. After further R&D efforts in the toming cycle for electric power generation leads to a
1980s and 1990s, fuel cells have recently attracted new further increase in the overall efficiency. The pressur-
attention due to their potential for use in stationary and ized SOFC can be used to replace combustors in gas
distributed electric power stations as well as in trans- and steam turbines. Such integrated SOFC-combustion
portation applications. At this stage, four types of fuel turbine power systems are expected to reach efficiencies
cells, namely, the polymer electrolyte fuel cell (PEFC), approaching 70% [3]. The high efficiency will contribute
to reduce CO2 emissions. In this review, science and
E-mail address: yamamoto@chem.mie-u.ac.jp (O. Ya- technology of SOFCs as well as their future prospects
mamoto) will be discussed.

0013-4686/00/$ - see front matter © 2000 Elsevier Science Ltd. All rights reserved.
PII: S 0 0 1 3 - 4 6 8 6 ( 0 0 ) 0 0 3 3 0 - 3
2424 O. Yamamoto / Electrochimica Acta 45 (2000) 2423–2435

Table 1
The characteristics and current status of the different types of fuel cell

PEFC PAFC MCFC SOFC

Electrolyte Nafion H3PO4 Na2CO2Li2CO3 ZrO2Y2O3


Operating temperature (°C) 70–80 200 650–700 900–1000
Fuel H2 H2 H2, CO, CH4 H2, CO, CH4
Expected efficiency (HHV) (%) 30–40 35–42 45–60 45–65
Power, current status (kW) 12.5a 100b 1000c 100d, 15e
Efficiency (%) 40 40 45 43d, 50e

a
Allied signal.
b
Fuji electric.
c
MCFC Research Association, Japan.
d
Siemens Westinghouse.
e
Mitsubishi Heavy Industry and Electric Power Development, Japan (at 5 atm).

2. Principle and histrical background of SOFC is still used as the electrolyte. The oxide ion conductiv-
ity of YSZ is around 0.1 S/cm at 1000°C. Together with
The operating principle of a SOFC with an oxide ion the electrolyte, the other SOFCs components have been
conductor is schematically shown in Fig. 1. When an studied for many years, but due to the high operating
external load is applied to the cell, oxygen is reduced at temperature, the choice of materials remains limited. In
the porous air electrode to produce oxide ions. These Baur and Preis’ first SOFC, iron or carbon were used as
ions migrate through the solid electrolyte to the fuel the anode while Weissbart and Ruka [6] of Westing-
electrode, and they react with the fuel, H2 or CO, to house Electric (now Siemens Westinghouse Power,
produce H2O or CO2. Alternatively, a proton conduct- SWH) in 1962 used platinum. At present nickel is the
ing solid electrolyte can be used, where H2 is oxidized most commonly used material because of its high cata-
to produce protons that subsequently react with oxygen lytic activity and low cost. The nickel-YSZ cermet
to form water. In some cases, CH4 can be oxidized anode can operate at a temperature as low as 500°C.
directly on the anode to form CO2 and H2O. The
The cathode materials must be stable in the oxidizing
open-circuit voltage, Eo, of the cell can be calculated
environment, have good electronic conductivity and
from the free energy change, DG, of the electrochemical
sufficient catalytic activity for oxygen reduction under
reaction or from the partial pressure of the oxygen
operating conditions. Many types of cathode materials
Po(c) at the cathode and Po(a) at the anode:
have been examined. Baur and Preis used Fe3O4 as the
Eo = −DG/nF= (RT/nF) ln Po(c)/Po(a) (1) cathode. The electrical conductivity of Fe3O4 is as high
as 3 × 102 S/cm at room temperature, but its catalytic
In this equation, R is the gas constant, T the absolute activity is insufficient. Weissbart and Ruka [6] used
temperature, F the Faraday constant, and n the electron
platinum as the cathode. At 1011°C, the cell voltage,
equivalent of oxygen (n=4). The cell voltage at 1000°C
is about 1 V for the SOFC with pure hydrogen and air.
The cell voltage drops as current is drained due to
polarization. The total polarization of a cell, h, is the
sum of three terms: anode polarization, ha, cathode
polarization, hc, and resistance polarization, hr.

h=ha +hc +hr (2)

The polarization depends on the electrode materials,


the electrolyte, the cell design, and the operating
temperature.
The first SOFC operating at 1000°C was built by
Baur and Preis [4] in 1937. In this cell, ZrO2-10
weight%(w/o) MgO or ZrO2-15 w/o Y2O3 was used as
the electrolyte. Nernst first discovered that ZrO2 with
15 w/o Y2O3 was a solid oxide ion conductor in 1899
[5]. In the most advanced SOFCs at present, yttria
stabilized zironica with 8–10 mol% (m/o) Y2O3 (YSZ) Fig. 1. Principle of operation of SOFC (by S.C.Singhal).
O. Yamamoto / Electrochimica Acta 45 (2000) 2423–2435 2425

Table 2 temperature alloys coated with LaCrO3 can be used.


Cell components, materials, and fabrication processes for The problems of the alloys is thermal expansion mis-
SWH SOFC match with other cell components. Table 2 summa-
rizes the cell components, materials, and fabrication
Component Material Thickness Fabrication
process
processes for the most advanced SWH SOFC [9].
SOFCs with several different configurations have
Air electrode Doped LaMnO 2.2 mm Extrusion been developed. The first SOFC module was demon-
tube strated by Brown Boveri in 1975 [10]. The module
Electrolyte ZrO2(Y2O3) 40 mm EVD was constructed from conical tubular cells by fitting
Fuel electrode NiZrO2(Y2O3) 100 mm Slury coat- one cell into the other. Contact of the anode and
EVD cathode of neighboring cells yielded a construction in
Interconnec- Doped LaCrO3 85 mm EVD
series. An interconnection material (doped CoCr2O4
tion
or LaCrO3) was used to ensure sealing and electronic
contacting in air and in fuel atmosphere. In the mod-
ule with 120 series-connected cells, a total voltage of
Pt, H2/(ZrO2)0.85(CaO)0.15/Pt, O2, was 0.7 V at 50
110 – 120 V and a maximum power output of 115 W
mA/cm2. The decrease in cell voltage from the open-
corresponding to 0.22 W/cm2 was obtained at 1000°C
circuit voltage of 1.1 V was mainly due to the inter-
nal resistance of the electrolyte, (ZrO2)0.85(CaO)0.15. with H2/air as the reaction gas. This modular concept
The polarization due to the electrode reactions was suffered from the disadvantage that for the construc-
not significant due to the high catalytic activity of tion of large batteries, many single cells had to be
platinum for oxygen reduction. There is no hope for produced and connected in series by means of a rela-
the use of platinum cathodes in a large scale SOFC, tively expensive manufacturing process. A further sim-
because the evaporation of platinum at high tempera- plification and a reduction of cell manufacturing cost
ture is non negligible and its cost is too high. Some was made possible by using thin-film techniques such
complex oxides in the perovskite family may satisfy as chemical vapor deposition or plasma spraying.
the requirements with regard to electrical conductiv- A porous electrode layer, a gas tight ZrO2 elec-
ity. Tedmon et al. [7] of General Electric in 1969 trolyte film and a second porous electrode as well as
reported on the cathode performance of perovskite, a gas tight interconnection material were applied one
PrCoO3. A stable power density of 0.3 W/cm2 over 6 after the other onto a highly porous ceramic support
months was obtained at 1000°C. The disadvantages [11] (segmented-cell-in-series design). In 1970, West-
of these cathode materials were thermal expansion inghouse had proposed a 100-kW coal burning fuel
mismatch and incompatibility with the electrolyte. At cell power plant using this SOFC concept. As the
present, the doped lanthanum manganite cathodes are performance and life-time of cells connected in series
most commonly used. However, there is still a need did not seem to be satisfactory at that time, the pro-
for the development of new cathode materials with ject was abandoned [12]. Subsequently, Westinghouse
good performance at lower temperatures in order to proposed a seal-less tubular design in 1980. The ma-
develop an intermediate temperature SOFC (500– terials and the fabrication process of this type of cell
700°C). are shown in Table 2. Recently a 100-kW scale SOFC
The stringent requirements for the interconnect ma- has been tested, 30 years after it was first proposed
terial in SOFCs operated at 1000°C eliminate all but by Westinghouse. The segmented-cell-in-series design
a few oxide systems. The interconnect in SOFCs must proposed by Westinghouse in 1969 was modified by
be stable under reducing and oxidizing atmospheres, Electric Technical Laboratory, Japan and a 10-kW
and must possess adequate electronic conductivity in scale unit was tested by Electric Power Development,
both atmospheres. The doped lanthanum chromite is Japan. In Fig. 2, typical planar and tubular configu-
particularly suitable with respect to high electronic rations of the SOFC are shown. Many modified pla-
conductivity under fuel and oxidant atmospheres. nar concepts were proposed over the last two
Lanthanum chromite (LaCrO3) has been used as an decades. A monolithic SOFC design was proposed by
SOFC interconnect material since the 1970s. Recently, Argonne National Laboratory in 1984 [13] (shown in
metallic interconnects of Cr alloys with 5 w/o Fe and Fig. 2). This design has the potential to achieve high
0.4–1.0 w/o Y2O3 or Cr2O3 have been evaluated as power density, because of the small cell size and large
an alternative material to LaCrO3 [8]. These alloys active area. The power density for the monolithic
have a thermal expansion coefficient very similar to SOFC is calculated to be about 8 kW/kg or 4 kW/l.
that of YSZ but the metallic interconnect is less re- The feasibility of the monolithic design has been
fractory and unstable in the oxidizing atmosphere at demonstrated only on a laboratory scale, however,
high temperatures. Some commercially available high because of the difficulty of development of suitable
2426 O. Yamamoto / Electrochimica Acta 45 (2000) 2423–2435

materials and fabrication processes. A modified design terials for low temperature SOFCs were available. A
of the monolithic configuration has been developed by lower operating temperature in the range of 500 – 800°C
Chubu Electric Power Co and Mitsubushi Heavy In- would have many advantages. Costly lanthanum
dustry, and was named the Mono Block Layer Built chromite interconnects could be replaced by a conven-
(MOLB). A 5-kW scale MOLB type SOFC was built tional metallic interconnect, and the selection of gas
and successful results were obtained [14]. seal materials in planar SOFCs would be easier. SOFCs
Up to the present, large scale SOFC units have been operating at 500°C or lower are being considered for
operated at around 1000°C because no acceptable ma- applications in electric vehicles [15].

Fig. 2. SOFC stack designs (by N.Q.Minh).


O. Yamamoto / Electrochimica Acta 45 (2000) 2423–2435 2427

formation reaction in Y2O3 doped ZrO2 can be written


in Kroger and Vink notation as
’’
Y2O3 = 2Y%Zr + Vo + 3Oxo (3)
Due to Coulombic and elastic attractive forces between
’’
Y%Zr and Vo , we can postulate the existence of two
associates:
’’ ’
Y%Zr + Vo = (YZrVo) (4)
and
’’
2Y%Zr + Vo = (2YZrVo)x (5)
At lower temperatures association is almost complete.
’’
At higher temperature the complex dissociates into Vo
Fig. 3. Temperature dependence of the electrical conductivity and Y%Zr. The conductivity, s, can be explained by Eq.
of the ZrO2M2O3 systems. 9SSZ: 9m/o Sc2O3ZrO2, 9YbSZ: (6)
9m/o Yb2O3ZrO2, 9YSZ:9m/o Y2O3ZrO2. ’’
s= em[V o ] (6)
’’
3. High temperatue SOFC with zirconia based elec- where m is the mobility, [V ] the concentration of
o

trolytes oxygen vacancies and e the effective charge. The con-


ductivity in the ZrO2M2O3 system depends on the
The most advanced SOFC employ oxide ion con- dopant concentration and the dopant ionic radius. In
ducting zirconia based electrolytes. The conductivity of Fig. 4, the dependence of the conductivity at 1000°C on
the electrolyte determines the operating temperature of the dopant concentration is shown for
SOFCs. The temperature dependence of the electrical ZrO2Ln2O3(Ln =lanthanides) [16]. A conductivity
conductivity, s, for zirconia based oxides is shown in maximum is found in these systems. The dopant Sc3 +
Fig. 3[16] where 9YSZ, 9YbZ, and 9SSZ denote 9 m/o which has the closest ionic radius to the host ion, Zr4 + ,
Y2O3, 9 m/o Yb2O3, and 9 m/o Sc2O3 doped ZrO2, shows the highest conductivity. The activation energy
respectively. Yttria doped zirconia, which has been used for conduction in the temperature range of 1000 – 700°C
extensively in SOFCs, shows a conductivity of 0.14 was found to decrease with decreasing ionic radius of
S/cm at 1000°C. Scandia doped zirconia has a higher the dopant and for ZrO2Sc2O3 its value was about 60
conductivity and at 780°C already its value corresponds kJ/mol. This behavior could be explained by the inter-
’’
to that of YSZ at 1000°C. action between Vo and LnZr % and by structural effects
It is well known that doping of ZrO2 with Y2O3 [17].
results in the substitution of Y3 + on the Zr4 + cation In Fig. 3, the thickness of the electrolyte showing a
sublattice with concomitant formation of oxygen va- resistance of 0.2 V cm2 is shown on the right side
cancies as charge compensating defects. The defect vertical axis. The 0.2 V cm2 resistance corresponds to
0.1 V lost due to the electrolyte resistance at 0.5 A/cm2,
where it is assumed that the cell voltage is 0.7 V to
maintain a total energy efficiency of greater than 50%
and ha, hc and hr contribute to equal parts to the cell
voltage drop [15]. The relationship between the temper-
ature and the electrolyte thickness suggests that at an
operating temperature of 700°C, the thickness of the
electrolyte should be less than 50 mm in the YSZ and
YbSZ systems while an electrolyte as thick as 150 mm
could be used in the SSZ system. A 50 mm thick
electrolyte can not be used in a self-supported configu-
ration, because of the difficulty of handling such a thin
electrolyte sheet. On the other hand, an electrolyte
thickness of 150 mm is acceptable for a self-supported
planar SOFC. In 1977 [18] SWH developed a vapor
deposition method for the fabrication of supported thin
electrolytes and gas-tight thin layers of YSZ with 10
Fig. 4. Composition dependence of the electrical conductivity m/o Y2O3 ( :40 mm thick) were fabricated on a pro-
at 1000°C for ZrO2Ln2O3(Ln= lanthanide). duction scale. A large active area cell ( :200 cm2)
2428 O. Yamamoto / Electrochimica Acta 45 (2000) 2423–2435

Fig. 5. Voltage-current characteristics of a SWH cell at differ-


ent temperatures.

achieved a cell voltage of 0.7 V for a current drain of


350 mA/cm2 at 1000°C, and for 270 mA/cm2 at 900°C
as shown in Fig. 5. A doped LaMnO3 cathode and a
Ni/YSZ cermet anode were used in this case [9]. The
total cell resistance is about 0.8 V cm2 from the cur- Fig. 7. Temperature dependence of electrical conductivity for
rent voltage curve at 900°C. The electrolyte resistance oxide ion conductors (high temperature range).
estimated from the conductivity and the thickness is
only 0.05 V cm2. This means that at high temperature lanthanum chromite interconnects are shown in Fig. 6,
the electrode polarization and the contact resistance where about 200 mm thick 11SSZ (11 m/o Sc2O3) of
are dominant. No cell performance data at lower tem- 20 cm2 active area was used as the electrolyte. At
peratures have been reported for SWH type cells. 850°C, a cell voltage of 0.7 V was obtained at 500
Minh and Montgomery of Allied Signal Aerospace mA/cm2. The discharge performance at 850°C of the
[19] reported the performance of cells with a planar cells with an 11SSZ electrolyte is comparable to that
supported thin (5–10 mm) YSZ electrolyte. The elec- with an YSZ electrolyte at 1000°C.
trolyte was made by a tape casting technique. An area
specific resistance was 0.38 V cm2 at 800°C. The five
cell stack (100 cm [2] footprint area) showed a cell 4. Materials and structure for intermediate temperature
voltage of 3.5 V (0.7 V per cell) at 350 mA/cm2 and SOFC
700°C. At lower operating temperatures, YSZ should
be used in thin film form as a supported electrolyte. The cell performance depends on the ohmic resis-
On the other hand, a solid with higher oxide ion tance of the electrolyte and on the electrode reaction
conductivity such as SSZ is suitable for thicker films. resistance (polarization). The electrode resistance is in-
Some results [20] for a single test cell with doped dependent of the thickness of the electrolyte. During
the last three decades, the ionic conductivity and the
transport number have been examined in many binary
and ternary oxide systems. An excellent review on the
properties of solid oxide ion conductors has been pre-
sented by Etsell and Flengas [21] in 1970. Minh [2]
reviewed the more recent results for SOFC elec-
trolytes. The temperature dependence of conductivity
in typical solid oxide ion conductors is summarized in
Fig. 7 and Fig. 8 for the high and lower temperature
ranges, respectively [22]. Some oxide systems show a
higher ionic conductivity than zirconia based oxides.
The electrolyte in SOFCs has to meet the following
requirements in addition to a high ionic conductivity:
Fig. 6. Voltage-current characteristics of a cell with 11SSZ low electronic conductivity, stability under oxidizing
electrolyte at different temperatures (effective electrode area: and reducing atmospheres, easy to make dense thin
20 cm2). films, and good mechanical and thermal properties at
O. Yamamoto / Electrochimica Acta 45 (2000) 2423–2435 2429

the operating temperature. Bismuth oxide systems show the highest conductivity. These systems, however, ex-
hibit high electronic conductivity under reducing atmo-
sphere, because of the reduction of Bi3 + to Bi2 + [23].
The most promising traditional materials for low tem-
perature operation of SOFCs are CeO2 doped with an
alkaline earth or rare earth oxide. The conductivity of
Ce0.8Gd0.2O1.9 [24] is 1.2×10 − 2 S/cm at 800°C and
3.7× 10 − 3 S/cm at 600°C. At higher oxygen partial
pressures the material is reported to have a purely ionic
conductivity. At lower oxygen partial pressures, as pre-
vail at the anode side of the SOFC, CeO2 becomes
partially reduced [25]. This leads to predominantly elec-
tronic conductivity in a large volume fraction of the
electrolyte extending from the anode side. In Fig. 9,
total electrical conductivities of Ce0.8Sm0.2O1.9 are
shown as a function of oxygen partial pressure [26]. The
increasing conductivity at lower oxygen partial pressure
is due to the contribution of the electronic conductivity.
At high oxygen partial pressure, the total electrical
conductivity is predominantly ionic, whereas at low
oxygen partial pressure it is predominantly electronic.
The efficiency of SOFCs with the mixed ionic-electronic
conductors of the CeO2 based oxide depends on the
Fig. 8. Temperature dependence of electrical conductivity for operating temperature and the thickness of the elec-
oxide ion conductors (lower temperature range). trolyte due to the partial reduction of the electrolyte.
Godlickemeier and Gauckler [26] analyzed the effi-
ciency of cells with ceria-based electrolytes by consider-
ing electrode overpotentials. The maximum efficiency of
these cells was 50% at 800°C, 57% at 700°C, and 60% at
600°C. In practical operation, it is also necessary to
consider the fuel efficiency. Generally, the fuel effi-
ciency is less than 80%. Therefore, SOFCs with the
CeO2 based electrolytes should be operated at tempera-
tures lower than 600°C in order to obtain a total
efficiency exceeding 50%. A SOFC based on
Ce0.8Gd0.2O1.9 at 500°C was examined by Doshi et al.
[17] Using a multilayer tape-casting technique these
authors fabricated an anode supported electrolyte bi-
Fig. 9. Total electrical conductivity of Ce0.8Sm0.2O1.9 − x at layer with an electrolyte thickness of 30 mm and anode
600, 700, and 800°C as a function of oxygen partial pressure. thickness of : 250 mm. Fig. 10 shows the performance
at 500°C of a cell with the NiCe0.8Gd0.2O1.9 cermet
anode and a cathode developed by Argonne National
Laboratory. The total cell resistance, including elec-
trode polarization for both electrodes, was 1.3 V cm2,
0.7 V cm2 resulting from the electrolyte, 0.6 V cm2 from
the cathode, while the loss from the anode was negligi-
ble. A cell voltage of 0.7 V was obtained at 150
mA/cm2 and the maximum power density was 140
mW/cm2. Another approach for the ceria based elec-
trolyte is to use a bi-layer electrolyte with YSZ. Tsai et
al. [27] developed an electrolyte consisting of a 4 – 8 mm
thick Y2O3 doped ceria layer with a 1 – 1.5 mm thick
Y2O3 doped zirconia layer on the fuel side. The thin
Fig. 10. Performance of SOFC with anode-supported bi-layer electrolyte provided a near theoretical open
Ce0.8Gd0.2 electrolyte and La0.8Sr0.2Fe0.8Co0.2O3 − cathode at circuit voltage and the electrolyte resistance was 0.25 W

500°C. cm2 at 600°C and 0.45 V cm2 at 550°C.
2430 O. Yamamoto / Electrochimica Acta 45 (2000) 2423–2435

Iwahara et al. [34] found that doped BaCeO3 and


doped SrCeO3 showed high proton conduction at ele-
vated temperatures. The conductivity of these per-
ovskite type proton conductors was similar or less than
those of zirconia based oxides. At lower temperature
Ba0.95Ce0.90Y0.10O3 – d showed a good conductivity as
shown in Fig. 8. However, the contribution of elec-
tronic conduction was non negligible.
Zirconia based oxides remain the best candidates for
the electrolyte in SOFCs. Yttria doped zirconia has
been used extensively in SOFCs, because of the rela-
tively high oxide ion conductivity, low electronic con-
ductivity, and stability under reducing and oxidizing
atmosphere. It is known that scandia doped zirconia
exhibit the highest conductivity of the zirconica based
oxides [16]. This material has not been used as an
Fig. 11. Performance of SOFC with 0.189 mm thick electrolyte in SOFC, because of aging at high tempera-
La0.9Sr0.1Ga0.8Mg0.2O2.85 electrolyte and Sm0.5Sr0.5CoO3 tures reduces its stability and because of high cost of
cathode. (, ) 800°C, (, )600°C. scandia. The latter could probably be drastically re-
duced if scandia were used on a large scale, because the
natural abundance of scandium is similar to that of
Certain perovskite type oxides exhibit high oxide ion lanthanum. The lack of long term stability of SSZ due
conductivity. An intermediate temperature SOFC with to aging is not yet well understood. Aging studies for
a BaTh0.9Gd0.1O3 electrolyte, a La0.9Sr0.1CoO3 cathode, the ZrO2Sc2O3 system suggested that samples with 10
and a Pd anode was investigated by Cook et al. [28]. A or 11 m/o Sc2O3 were stable without conductivity
cell voltage of 0.7 V was obtained at 200 mA/cm2 and degradation upon aging at a high temperature [35]. SSZ
550°C. The thickness of the electrolyte was about 0.13 with 10 or 11 m/o Sc2O3 is rhombohedral at room
cm and the ionic conductivity was estimated to be temperature and forms the cubic phase at around
8.7×10 − 2 S/cm at 550°C from the current-voltage 600°C. The temperature dependence of the conductivity
curve. The observed open-circuit voltage was slightly of SSZ exhibits an abrupt conductivity change at about
lower than the calculated one, which indicated a contri- 600°C, which corresponds to this phase transition. The
bution of electronic conduction in the electrolyte under cubic phase can be stabilized by the substitution of
fuel cell conditions. Some yeas ago, small amount of Y3 + for Sc3 + and by addition of
La0.9Sr0.1Ga0.8Mg0.2O2.85 (LSGM) was reported as a Al2O3 [35].
superior oxide ion electrolyte by Ishihara et al. [29] and High electrolyte strength and toughness is desirable,
Feng et al. [30]. It has an ionic conductivity of more especially in planar configuration SOFC. In Table 3,
than 0.1 S/cm at 800°C, good chemical stability, and the mechanical properties of zirconia based oxides are
negligible electronic conduction over a broad range of shown along with their electrical conductivity and the
oxygen partial pressures. A small single cell test with a thermal expansion coefficients. The bending strength of
11SSZ is almost comparable to that of 8YSZ and the
500 mm thick LSGM electrolyte showed promising per-
toughness is higher than that of 8YSZ. The bending
formance compared to a YSZ electrolyte at operating
strength of YSZ was improved by addition of Al2O3
temperatures of 600–800°C. A cell voltage of 0.7 V was
[35]. The composite of 11SSZ with Al2O3 is recom-
obtained at 500 mA/cm2 and 600°C with a Ni anode
mended as an electrolyte in intermediate temperature
and a Sm0.5Sr0.5CoO3 cathode as shown in Fig. 11 [31].
SOFCs, because of its high oxide ion conductivity,
There is still a need to improve the stability for this phase stability, and excellent mechanical properties.
type of perovskite oxide used with a Ni anode under The cathode in SOFCs is of particular concern for
reducing atmosphere. Ni reacts with an LSGM elec- obtaining a high performance, especially at low operat-
trolyte to form LaNiO3 [32]. Recently, the intrinsic ing temperature. The cathode materials for SOFCs
creep resistance of LSGM was measured by Wolfen- have to meet the following requirements: high electrical
stine [33] in the temperature range 800–1000°C. The conductivity at operating temperature, thermal and
results revealed that the intrinsic creep resistance of the chemical compatibility with the electrolyte, and high
Y2O3 and Sc2O3 doped cubic zirconia was much better catalytic activity for oxygen reduction. Early SOFC
than that for LSGM over the entire temperature range. stacks used a noble metal like platinum as the cathode.
This is most likely a result of the difference in crystal In the 1960s doped In2O3 [36] was used, and in the
structure. early 1980s LaMnO3 and LaCoO3 were proposed [2].
O. Yamamoto / Electrochimica Acta 45 (2000) 2423–2435 2431

Table 3
Electrical and mechanical properties of zirconia based oxidesa

Materials Conductivity (S/cm) Bending strength (MPa) Thermal expansion coefficient (10−8/K)

1000°C 800°C

3YTZP 0.056 0.018 1200 10.8


3YbTZP 0.063 0.014
2.9STZP 0.09 0.031
8YSZ 0.16 0.03 279 10.5
8SSZ 0.38 0.13 275 10.7
8YbSZ 0.20 0.63
11SSZ 0.32 0.12 255 10.0
11SSZ1A 0.26 250
11SSZ20A 0.15 365 10.1

a
3YTZP: 3 m/o Y2O3ZrO2, 3YbTZP: 3 m/o Yb2O3ZrO2, 2.9SSZ: 2.9 m/o Sc2O3ZrO2, 11SSZ1A:(11 m/o Sc2O3ZrO2)-1 w/o
Al2O3, 11SSZ20A: (11m/oSc2O3ZrO2)-20 w/o Al2O3.

Takeda et al. [37] studied the electrical conductivity and More recently, Uchida et al. [43] reported an interest-
the catalytic activity for oxygen reduction of perovskite ing result concerning hydrogen oxidation on an active
oxide electrodes, La1 − x Srx MO3(MCr, Mn, Fe, Co). hydrogen electrode. The IR-free polarization of the
The cathodic polarization curves at 800oC for sputtered active anode attached to different types of zirconia
La1 − x Srx MO3 on YSZ are shown in Fig. 12. The electrolytes was greatly influenced by the conductivity
La1 − x Srx CoO3 electrode has high catalytic activity for of the zirconia used. The doped zirconia with higher
oxygen reduction. The conductivity measurements also ionic conductivity exhibited a higher exchange current
showed that the cobalt system had the highest conduc- density for the hydrogen electrode at 800 – 1000°C as
tivity in these perovskite systems, but the compatibility shown in Fig. 13, where Sm doped CeO2 with Ru was
with YSZ was less good. The thermal expansion coeffi- used as the anode catalyst. The results indicate that the
cient of LaCoO3 is :22–24×10 − 6/K and that of reaction rate of H2 oxidation was controlled by the
YSZ : 10–11 ×10 − 6/K. La1 − x Srx CoO3 reacts readily
with YSZ forming the low conductivity products,
La2Zr2O3 and SrZrO3 [38]. No reaction product has
been observed when coupling doped CeO2 and La1 −
xSrx CoO3. For this reason, the La1 − x Srx CoO3 systems
have been used together with CeO2 based electrolytes in
SOFCs at low operating temperatures. However, the
mismatch in thermal expansion between CeO2 and
La1 − x Srx CoO needs to be improved.
More recently, La1 − x Srx Fe1 − yCoyO3(LSFC) has
been examined extensively for SOFCs operating below
900°C [39]. This system showed a good electrical con-
ductivity at temperatures between 600 and 800°C, high
oxygen surface exchange coefficient and high oxygen
self diffusion coefficient. The oxygen self diffusion co-
efficient (D*) of LSFC at 500°C of 2.6 ×10 − 9 cm2/s
compared to that of La0.8Sr0.2MnO3 at 10 − 12 cm2/s at
1000°C [40]. The LSFC /Ce0.9Sm0.1O1.95 combination
exhibits fast electrode kinetics. LSFC does not react
with ceria-based electrolytes and has a compatible ther-
mal expansion coefficient [41]. Excellent behavior of the
cell Ni-YSZ/Ce0.8Gd0.2 O1.9/LSFC has been proved by
Berkel et al. of ECN [42]. A cell voltage of 0.7 V was
obtained at 150 mA/cm2 and 603°C with a self-sup- Fig. 12. Cathodic polarization curves at 800°C for a sputtered
ported 0.1–0.25 mm thick Ce0.8Gd0.2O1.9 electrolyte. La1 − x Srx MO3 film.
2432 O. Yamamoto / Electrochimica Acta 45 (2000) 2423–2435

1152 air electrode supported tubular type cells (2.2 cm


diameter and 150 cm active length). The 100-kW SOFC
has achieved an electrical generation efficiency of 46%
(LHV) and at net system output of 106 kW to the grid.
Under the normal operation condition of 1000°C, 80%
fuel utilization is achieved. Emission measurements
confirmed an NOx level B 0.2 ppm with undetectable
levels of SOx, CO, and unburned hydrocarbons. At
present, the system has been in operation for 3700 h at
the test site, and except for one stack segment the
SOFC generator performed with good stability. The
costs of this system amounts to : 10 million US$.
MHI and Electric Power Development in Japan [46]
developed another type of tubular SOFC. A pressurized
10-kW class module was tested which employs 414 cells
(52 cm length) and operates at 900°C at 5 atm. A 15
kW out-put power was obtained at 200 mA/cm2. The
Fig. 13. Exchange current density for RuCe0.8Sm0.2O1.9 an-
module has been operated for \5000 h.
ode versus conductivity of zirconia based electrolytes 10Sc: 10
m/o Sc2O3ZrO2, 8Yb: 8 m/o Yb2O3ZrO2, 8Y: 8 m/o Several types of planar SOFCs have been developed.
Y2O3ZrO2, 4Y: 4 m/oY2O3ZrO2. SWH in Germany operated a 10 kW class planar
configuration SOFC [47]. The cells were mounted be-
tween bipolar plates. A stack with 80 cell layers was
supply of oxide ions through the electrode/zirconia assembled, each layer consisting of 16 paralleled cells.
interface and that the rate was proportional to the ionic However, at this time SWH has given up developing a
conductivity. Similar results were observed for oxygen planar SOFC and is now concentrating on a tubular
reduction on the oxygen electrode of the SOFC. The Chubu Electric Power Company and Mit-
La0.85Sr0.15MnO3 with Pt as the catalyst [44]. It can thus subishi Heavy Industries have been evaluating a 5 kW
be seen that both low electronic resistance and high class planar type SOFC [48]. The cells have used a
oxide ion conductivity of the electrolyte are required to ceramic interconnect of doped lanthanum chromite.
obtain excellent cell performance in low temperature The support layers were fabricated with the same mate-
SOFCs. rials as the electrodes and the layers were corrugated to
allow the gas to pass through. A power density of 0.22
W/cm2 with fuel utilization of 38% was obtained. Ce-
5. The future and prospect of SOFC ramic Fuel Cells in Australia [49] developed a 5 kW
planar type SOFC with stainless steel interconnects.
After the first report for SOFCs in 1937 and the The 400 cells were fabricated from 10 cm× 10 cm×
scientific paper in 1962 by Weissbart and Ruka [6], 100 mm 3YSZ electrolyte sheets produced by tape-cast-
many efforts have been made to develop a high perfor- ing. Sulzer Hexis in Switzerland [50] has developed a
mance SOFC. Recently, large scale SOFCs have been planar type ceramic/metal hybrid stack with metallic
developed for power generation systems. Since Decem- interconnects. Table 4 summarizes the current status of
ber 1997, testing of a 100 kW SWH SOFC power the systems or modules of kilowatt or greater class
generation system has been carried out by a consortium SOFCs. At this time, the SWH type is the most ad-
of Dutch and Danish utilities [45]. The system employs vanced SOFC. A large number of air electrode sup-

Table 4
Stack performance of large scale SOFCa

Developer Type Power (kW) Interconnect Remark

SWH Tubular 100 LaCr0.9Mg0.1O3 he =46%


SWH Tubular 25 LaCr09Mg0.1OO3 Operating hours: 13 100
MHI & EPDC Tubular 15 NiAl/Al2O3 Operating pressure: 5 atm
SWH Planar 10 Cr with 5%Fe and 1%Y2O3 5.4 kW at 950oC, 4.1 kW at 850oC
MHI&CEPCO Planar 5 Doped LaCrO3 he =22%

a
SWH: Siemens Whestinghouse Power Co., MHI: Mitsubishi Heavy Industries, EPDC: Electric Power Development Co.,
CEPCO: Chubu Electric Power Co., he: energy conversion efficiency.
O. Yamamoto / Electrochimica Acta 45 (2000) 2423–2435 2433

preferred fuel cell technology for EV applications is the


polymer electrolyte type. It uses hydrogen or reformed
hydrocarbon as a fuel and is very sensitive to carbon
monoxide poisoning. In contrast, SOFCs are not ad-
versely affected by CO and can use fuel directly without
a reformer. However, the relatively high operating tem-
perature of current designs would require more time
and energy for startup. By reducing the operating tem-
perature to 500°C or less, these problems would be-
come manageable. More recently, Murry et al. [52]
reported the possibility of a direct-methane fuel cell
with 8 m/o Y2O3 doped ZrO2 electrolyte. The elec-
trolyte was prepared by sputter deposition of the elec-
Fig. 14. Cell voltage and power density versus current density trolyte on a porous La0.8Sr0.2MnO3 cathode. The anode
for a SOFC operated on air and wet methane. was porous Ni-YSZ coated Y2O3 doped CeO2. The cell
performance is shown in Fig. 14. The power density of
ported cells have been electrically tested for up to 0.37 W/cm2 was obtained at 650°C. When Ni catalysts
10 000 h. The performance degradation was less than are used with hydrocarbon feed stocks, they are prone
to deactivation through the formation of carbonaceous
0.2% per 1000 h. At present, the electric power out-put
deposits on the catalyst surface. An important result
efficiency is 46%, a value higher than that of advanced
was therefore the absence of carbon deposits in the
conventional electric power plants. However, for practi-
temperature range examined (650 – 550°C) Further-
cal applications to in electric power plants of several
more, Baker et al. [53] reported that no carbon deposits
MW or larger the system needs further improvements.
were detected on the La0.8Ca0.2CrO3 anode during di-
The most important point is the cost. The cost of SWH
rect oxidation of CH4 in the temperature range 400 –
type system can be as high as 100 000 US$/kW. To be
600°C. These results suggest the possibility of using
comparable to conventional electric power plants the
SOFC for EV applications in the future.
cost must be reduced to B3000 US$/kW. Several
approaches are possible such as using mixed lan-
thanides instead of high purity component oxides and
adopting cheaper deposition processes for cell produc- 6. Conclusion
tion. Toto and Kyushu Electric Power in Japan devel-
oped a SWH type tubular SOFC by a wet processing Except for cost-effective manufacturing processes,
technique [51]. A dense thin YSZ film (about 30 mm the development efforts over the past 30 years have
thick) was prepared on a porous supported brought the technology of high temperature SOFC near
(La,Sr)MnO3 tube (22 mm diameter, 900 mm length) its final goal. On the other hand, technology of interme-
by slurry coating. (La, Ca)CrO3 was applied to form an diate temperature SOFCs is still in a developmental
interconnecting strip by slurry coating. Successful re- stage and several technological challenges remain to be
solved before this type of fuel cell can find practical
sults were obtained by this method for a 1.3 kW stack.
applications. A SOFC that uses hydrocarbon or
Medium scale SOFCs (1 MW to 50 kW) are also
methanol and operates at B500°C may eventually
attractive for distributed power generation. For this
become an attractive power source for EV. More infor-
application, it is necessary to meet many particular
mation on the science and technology of SOFC up to
requirements: maintenance free, high energy conversion
1994 can be found in the excellent book by Minh and
efficiency, and low cost. Maintenance free operation is
Takahashi [54] to which the reader is referred for
the greatest advantage of SOFCs systems. However, gas
further information.
turbine systems are strong competitors. The total en-
ergy efficiency of a gas turbine for the combined heat
and power generation is \60% and cost is estimated to
be B3000 US$/kW. References
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