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ELSEVIER Solid State Ionics 94 (1997) 239-248
loNKs
B.C.H. Steele
Department of Materials, Imperial College, London SW7 2BP, UK
Abstract
The applicability of classical liquid electrochemical concepts to porous cathode structures used in high temperature fuel
cells is discussed. It does appear that the performance of molten carbonate fuel cell cathodes can be satisfactorily interpreted
in terms of conventional electrochemical engineering invoking thin films of molten electrolyte distributed in the partially
flooded porous cathode structure. In contrast, the behaviour of porous oxide cathodes deposited on ceramic oxide electrolytes
is dominated by interfacial oxygen surface exchange reactions and diffusive processes. The importance of the characteristic
length term, L, (D*/k), which indicates the change-over from surface to bulk control is emphasised. It is suggested that for
porous oxide cathode structures, in which the grain size is usually around 1 km, the oxygen reduction process will invuriab~y
be dominated by the interfacial oxygen exchange process. For mixed conducting cathodes, chemical processes such as
changes in the oxide stoichiometry, can contribute significantly to the overpotential within the electrode. This can lead to
erroneous interpretations if the I-Vcharacteristics are analysed in terms of conventional electrochemical expressions. Finally
the design of optimised solid state cathodes is discussed and the need for oxygen surface diffusion data is emphasised.
Kewords: Fuel cells; Cathodes; Oxygen surface exchange; Oxygen self diffusion
electrochemical power systems particularly those 2.2. Electrolyte retention and distribution
incorporating solid electrolytes.
A simple thin film model is often used to describe
the behaviour of partially flooded porous electrodes
2. Molten carbonate fuel cell (MCFC) in contact with liquid electrolytes as depicted in Fig.
2a. The gas dissolves into the electrolyte film and is
2.1. General features transported to active sites on the surface of the
electrocatalyst. For low temperature systems PTFE
The general features of the MCFC are depicted in
Fig. 1. The molten salt electrolyte, 62 mole%
L&CO, and 38% K,CO,, is retained in a LiAlO,
particle matrix. The cathode is porous NiO, the Electrolyte
anode is porous Ni and the bi-polar plate material is
usually stainless steel. The rheological properties of
the electrolyte structure depends upon the relative
amounts of molten carbonate and LiAlO,. The size,
shape and distribution of the LiAlO, particles also yc co&/d, = ye cose,/d, = ya cose,/d,
influence the carbonate retention, mechanical prop-
erties and ionic conductivity of the electrolyte struc-
ture. The most effective shape for the LiAlO,
particles appears to be long rods or fibres of submic- NiO Ni
ron diameter and at present the electrolyte structure Cathode Anode
usually consists of about LiAlO,-carbonate (40:60, Fig. 2. (a) Thin film liquid electrolyte/porous electrode structure.
w/w). (b) Fixed volume capillary equilibrium concept.
e-
(H2, CO)
ANODE Wrous Ni (+ Cr)
ELECTROLYTE
MATRIX in
600-700°C LiA102 matrlx
e-
serves as a binder and hydrophobic phase to maintain monstration plants around 100 kW have already been
the integrity of the electrode structure and to estab- constructed and tested in the USA and Japan and a 2
lish a stable electrolyte/gas interface. A different MW plant has recently (May, 1996) been commis-
approach has to be adopted for MCFC in that a sioned at Santa Clara, California. However although
‘fixed volume capillary equilibrium concept’ is used performance degradation has been reduced to ap-
to control electrolyte distribution. By correct adjust- proximately 3 mV/lOOO h, there still remain major
ment of the pore diameters in the electrolyte and uncertainties as to whether lifetimes in excess of
electrode phases, an appropriate distribution of the 10 000 h can be obtained particularly at fuel conver-
electrolyte can be achieved (Fig. 2b). At thermo- sion levels above 75% and with operation at elevated
dynamic equilibrium, the diameters of the largest pressures.
flooded pores in the porous components are related
by the equation:
3. Solid oxide fuel cells
y,c0s0~ Id, = y,cosO, Id, = y,cos0, Id,,
3. I. General features
where y is the interfacial tension (liquid-gas), 13the
contact angle of the electrolyte, d the pore diameter Compared to other fuel cells, the solid oxide fuel
and the subscripts indicate the porous components cell (SOFC) possesses many advantages in that it is
(cathode, electrolyte, anode) by their first letter. The a two phase (gas/solid) system. This overcomes
distribution of pores has to be achieved by empirical many of the problems associated with liquid elec-
means as the morphology of the cathode is difficult trolytes such as corrosion, flooding, electrolyte dis-
to predict as the NiO cathode is fabricated from a tribution and maintaining a stable TPB region.
porous Ni plaque which is oxidised in situ. The Moreover ceramic ion conducting electrolytes can in
porosity of the plaque before oxidation is about principle operate over a wide range of temperatures:
70-80% with a mean pore size of 6-10 pm. After 500- 1000°C. Inevitably operation at elevated tem-
oxidation and lithiation, the NiO cathode appears to peratures introduces its own problems including
consist of agglomerates of NiO particles, with the interdiffusion, grain growth of particulate electro-
electrolyte filling the space (micropores) between the catalysts and thermomechanical restraints due to the
particles. The agglomerates are separated by gas- inherent brittleness of the ceramic components.
filled spaces (macropores), which correspond to the However, providing the properties of the relevant
pores of the original metal plaque. It is obviously materials are optimised for the particular design
important to select an economic fabrication tech- configuration, then it has been demonstrated that
nique that can provide reliable control over the SOFC stacks can be operated for longer than 60 000
distribution and size of pores and tape-casting is now h with acceptable degradation values 171. Further
the preferred route. Using this process technology, information on materials selection and performance
cell areas over 1 m2 have been successfully manu- for SOFC systems is provided in recent publication
factured and tested. [4,5,8-lo], as the present contribution is principally
It does appear [2] that the performance of MCFC concerned with solid state electrochemical aspects of
cathodes can be interpreted in terms of conventional SOFC stacks.
electrochemical concepts. The rate-determining step
appears to be the supply of molecular oxygen in the 3.2 Solid state electrochemistty
thin film molten electrolyte to the electrocatalytic
sites on the lithiated NiO cathode. Increasing the An immediate question arises about the relevance
operating pressure increases the solubility of oxygen of the concepts of classical liquid electrochemistry to
and produces an enhanced performance but at the solid state systems. This topic was the subject of an
expense of increased NiO solubility and other unde- international symposium 20 years ago [ 1 l] and is
sirable side reactions such as carbon deposition in being considered again at the present meeting.
the anode. Simple calculations [ 121 indicate that the Debye
Finally it should be emphasised that MCFC de- length is about the same size (- 10.~ “’ m) as the
242 B.C.H. Steele I Solid State tonics 94 (1997) 239-248
summarised in the following diagram (Fig. 3). The importance of this process in cathodic reduction
mechanisms has already been emphasised [ 16,171
l Reaction pathway (j,): Reaction of molecular and it can be shown [ 16,171 that a characteristic
oxygen with electrolyte surface (a) length, L,, which indicates the change-over from
B.C.H. Steele I Solid State Ionics 94 (1997) 2.79-248 243
I
s
La,,,Sr,,Co,,Fe,,,O, are larger than through the 8, l.OOE-05
other materials which possess higher oxygen diffu- E I
O l.OOE-06 --P- LSCF 6/4/Z/6
sion coefficient (ionic conductivity) values.
A collection (Fig. 5) of k and D data compiled
from reference [ 191 suggests that a correlation exists
between these quantities and that values for L, (D/k)
usually exceed 1 Frn with most values clustered
IE-06 1E-05 IE-04 0.001 0.01 0.1 1
around 100 km. This implies that for optimised
Membrane thickness I cm
porous cathode microstructures (i.e. grain sizes
around 1 pm. and TPB lengths greater than lo4 Fig. 4. Calculated oxygen fluxes [I91 through perovskite mem-
branes at 800°C based on expression [ 171 j,, =qI(LV,,RT/
cm ’ ) the oxygen reduction process will invariably
D*z’F’+RTVmIh’FZ).
be dominated by the interfacial oxygen exchange
process (see Eq. (i)) unless the surface transport of
oxygen ions to the TPB region becomes rate-control- For a single grain,
ling. This statement is examined in more detail in j, X 4w = j, X 4w X I,,
subsequent sections.
that is,
4.2. Suqace diffusion cathodes (pathway 2)
j, =.i, X 1,
Assuming this pathway to be dominant then it is with j, ‘v/R,, where 71 is the overpotential and
possible to examine the parameters including the R,=R~‘V,I(ZF)~~ ([ 16,171). Hence
electrode kinetics using the simple array of cubic j, = 7lR, X 2/w X 1h’
grains adopted in Ref. [9]. If the edge of the cubic
grain has a length w cm, the length of the triple The value of the collection length is unknown.
phase boundary (TPB) per unit area=s cm-’ =2/w However available data suggest that useful electrode
-I
cm thicknesses are limited to about 20-30 pm. Allow-
It follows that the macroscopic current density (je: ing for tortuosity and effective catalytic area factors,
A rn- ‘) is given by: then a collection length of 100 p,rn would not be
unreasonable. It is necessary to emphasise that in
j, =,j, X 2/w assigning a collection length of 100 km it has been
assumed that the oxygen surface diffusion coefficient
where j, is the current through the TPB region is not rate-determining.
(A cm--‘) Using data [20] for La,,Sr,,,,MnO, (LSM) as an
For electronically conducting oxide surfaces the example,
predominant oxygen species at elevated temperatures
will be O’-. The flux of ions towards the TPB k = lO~‘cm~ at 1000°C (1273 K),
region will therefore be restricted by the interfacial
oxygen exchange process (j,: A mp2), and so it will V, (molar volume of ABO, oxide)
be necessary to specify an area over which the
= 30 cm3 (typical value),
oxygen ions have been collected by introducing a
collection length, I,. we obtain
244 B.C.H. Steele I Solid State tonics 94 (1997) 239-248
Fig. 5. Values [ 181 of oxygen surface exchange coefficient (k cm s -‘) and self-diffusion (D* cm* SC’) for selected oxides
surface diffusion process. For long collection dis- material, and increasing the effective TPB length it
tances (> 100 Fm?) the surface diffusion flux to the has been demonstrated that excellent cathodic per-
TPB could become rate limiting, although it is formance can be achieved with thick film supported
unlikely that this mechanism would have such a electrolyte structures and power densities in excess
relatively high activation energy (-2 eV>. of 0.6 Wcm-’ at 800°C have been reported 1281.
Further support for a surface exchange limited
process comes from the experiments of those inves-
tigators [e.g. [23,2411 who have shown that additions
of dispersed precious metals can enhance the per- This pathway (see Fig. 3) effectively increases the
formance of LSM cathodes as such additions are width of the TPB region and results in an enhanced
likely to increase the relevant k values. It is also cathodic performance. As the individual electro-
probable that the use of A site deficient LSM [2S] catalytic grains typically have dimensions around I
will enhance the cathodic performance as this materi- pm then due to the D/k (L,) parameter it is likely
al will have a higher oxygen ion vacancy con- that the oxygen surface exchange reaction will still
centration. This will result in a larger oxygen self- be rate-limiting. There will also be a limit to the
diffusion coefficient (D*) and probably a significant height over which the surface reaction can provide
increase in the oxygen surface exchange coefficient oxygen ions for the internal oxygen ion flux due to
(k) according to the correlation noted by Kilner [ 181. resistive losses associated with the bulk oxygen ion
It has already been mentioned [19,26] that the diffusion coefficient [91. The advantages of
oxygen diffusion coefficient in LSM is very low mixed conduction have been demonstrated foi
(-1O-‘Z cmlsm’ ) at 1000°C and so there is little
La,, ,Sr,, jCo,, ,Fe,, ,O,(LSCF)/Ce,,,Gcl,, ,O, q5 and
opportunity for oxygen ions to enter the ceramic similar cathode structures 1101. and are also clearly
electrolyte via bulk diffusion (pathway j, in Fig. 3). evident in the behaviour of La,,,Sr,, ,MnO, at higher
It follows that the TPB length must be as long as overpotentials 1291. Recent publications 1303 I ] have
possible and Fig. 6 depicts the relationship between provided phenomenological models for the behaviour
overpotential and TPB length for LSM-YSZ struc- of porous mixed conducting oxide electrodes and
tures 1131. It is evident that any modification which coatings. The following expression is derived in both
increases the length of the TPB region, such as these publications:
dispersing zirconia particles in the electrode struc-
ture. can produce improvements to the cathode
behaviour [ 13,271. Thus by using A site deficient
I, is the extension of the TPB region and Lc (D/k) is
the critical length parameter expressing the relative
importance of bulk diffusion and interfacial oxygen
exchange, d is the fraction porosity. r is the tortuosi-
ty factor and s cm ~-’ is the length of the TPB region
per unit area. or the pore surface area for unit
volume. Assuming a particle dimension of 1 pm
(s-20 000 cm ’ ), porosity (4) =0.5 and tortuosity
(r)=5, then for a typical D/k value of 10~’ cm (100
km), the extension of the TPB region will be about 5
p,m. For a poor ionic conductor such as LSM where
D/k has a value of 10m5 at 1000°C 191 the extension
0 0.1 0.2 0.3 0.4 0.5 (lc ) of the TPB region only amounts to 4 X IO ’ m
Ltpb(pm/ pm*) (i.e. a few units cells). It is also instructive to
examine the enhancement to the allowed ionic flux
Fig. 6. Plots (131 of overpotential at 400 mA cm-’ versus length
of TPB per unit area at 850°C. Solid line calculated by model; (0) by the incorporation of a porous electrode (coating)
pure LSM electrode, (0) composite LSM-YSZ electrode. on top of the dense ion conducting membrane.
246 B.C.H.Steele I Solid State tonics 94 (1997) 239-248
E
j/L, . s *(1 - 4)/r + f#J
-k,
ectronic charge-transfer
and for a typical mixed conductor with the values
given above this expression has a value of about 5.
Significant enhancements can only be obtained if
ionic charge-transfer
rapid surface diffusion fluxes are invoked. For
example if the surface diffusion and oxygen ex-
, ionic migration
change coefficients have values of 1O-6 cm* s -’ and
lop6 cm s-‘, respectively, then the enhancement
factor becomes 45 for the same microstructural
parameters.
It appears that the charge-transfer of oxygen ions (b) Chemical Losses
across the interface between a mixed conductor and a
ceramic electrolyte is facile [32], and so the optimal
design for a cathode appears to consist of a thin (- 1 chemical
pm) dense layer of the electrocatalyst (e.g. LSCF) reaction
significantly to the potential drop in the electrode, dominate the electrochemical behaviour of porous
although they are not associated directly with the oxide cathode deposited on ceramic oxide elec-
flow of current. trolytes producing large effective ‘chemical’ resis-
If the interfacial process is the principal rate- tances and capacitances. The mechanisms involved
determining reaction, then assuming the mixed con- are more similar to the situation for heterogeneous
ductor is a good electronic conductor, i.e. [e-l and catalysts than classical liquid electrochemical con-
[O,], are essentially constant, then cepts. At present it is difficult to integrate micro- and
macro-modelling approaches to solid state porous
electrodes because of lack of data about the surface
diffusion of oxygen ions and the applicability of
AC = RT In P,, = - 4vF, using k values determined for dense ceramic samples
to particulate electrocatalyst structures. Clearly the
i.e. acquisition of oxygen surface exchange data under
dynamic conditions is also an urgent requirement as
7 = (RTI4F) ln(PoJ = (RTI4F) ln(V,)*.
the present IEDP technique measure k values at
As the current flux is proportional to [Vi] it follows equilibrium. Although it is possible to propose [3 11
that 7 0~(RTI2F) In i. rate-equations based on heterogeneous catalyst ap-
Thus although the interfacial reaction dominates it proaches and to suggest [ 161 interfacial resistive
may be possible to obtain an apparent Tafel relation- terms such as, RTV,,,lz2F2k, it is clearly necessary to
ship, and certain investigators have interpreted their demonstrate the range of overpotential values (- 100
observation as indicating that the electrode kinetics mV?) for which such expressions are valid.
are controlled by charge-transfer kinetics rather than
the chemical interfacial reaction.
References
5. Electrochemistry of anodic reactions [II A.J. Appleby and A.R. Foulkes, in: Fuel Cell Handbook
(Van Nostrand Reinhold, New York, 1989).
PI L.J.N. Blomen and M.N. Mugerwa. eds. Fuel Cell Systems
A porous Ni-ZrO, cermet has been adopted as the (Plenum Press, New York, 1993).
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of SOFC stacks. However the performance of the Fuel Cells: A Handbook Revision 3 (DOE/METC-94/1006
US Dept. of Energy, USA, 1994).
Ni-ZrO, cermet is very dependent upon the associ-
[41 N.Q. Minh and T. Takahashi, in: Science and Technology of
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[91 B.C.H. Steele, Solid State Ionics 86-88 (1996) 1223.
6. Conclusions
[lOI 2nd European Solid Oxide Fuel Cell Forum, ed. B. Thor-
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