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• Metal interconnect-supported. Lawrence Berkeley National Laboratory (66), Argonne National Laboratory, and Ceres (67) have pioneered metal-supported cells to minimize mass transfer resistance and the use of (expensive) ceramic materials. In such cells, the electrodes are typically 50 μm thick and the electrolyte around 5 to15 μm. While the benefits are obvious, the challenges are to find a materials combination and manufacturing process that avoids corrosion and deformation of the metal and interfacial reactions during manufacturing as well as operation. Interconnect material: • Ceramic (lanthanum or yttrium chromite) suitable for high-temperature operation (900 to 1000 °C). These materials, while chemically stable and compatible with the MEA from a chemical and thermal expansion perspective, are mechanically weak and costly. • Cr-based or Ni-based superalloy for intermediate-high temperature operation (800 to 900 °C). These materials are chemically stable at 900 °C, but they require additional coatings to prevent Cr-poisoning of the electrodes. In addition, they are expensive and difficult to form. • Ferritic steel (coated or uncoated) for intermediate temperature operation (650 to 800 °C). While uncoated steels are chemically unstable, especially during thermal cycling, coated steels provide corrosion resistance as well as acceptable conductivity when new. However, thermal cycling performance still requires improvement. Shape of the cell. • Rectangular, with gases flowing in co-flow, counter-flow, or cross-flow. • Circular, typically with gases flowing out from the center in co-flow, and mixing and burning at the edge of the cells. Spiral flow arrangements and counter-flow arrangements have also been proposed. Method for creating flow-channels: • Flat ceramic cell with channels in interconnect or flow-plate. • Corrugated ceramic with flat interconnects. Manifolding arrangement: • External manifolding. • Internal manifolding, through the electrolyte. • Internal manifolding through the interconnect, but not through the electrolyte. Figure 7-22 shows a sample of recently-pursued planar SOFC approaches. The anode-supported technology with metal interconnects will be described in some detail below. Mitsubishi tested a 15 kW system with its all-ceramic MOLB design for almost 10,000 hours with degradation rates below 0.5 percent per 1,000 hrs, but without thermal cycles, and with power densities ranging from 190 to 220 mW/cm2 (under practical operating conditions). Because the interconnect is flat and relatively thin (the flow-passage is embedded in the MEA), less of the expensive LaCrO3 is required than if the flow-passages were in the interconnect. Nevertheless, cost reduction is still one of the main priorities for this stack technology. Thermal cycling is also thought to be a challenge with the system, which is targeted to small-scale distributed stationary power generation applications. 7-32PDF Image | Fuel Cell Handbook (Seventh Edition)
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