Anode supported micro-tubular SOFC fabricated with mixed particle size electrolyte via phase-inversion technique

Cerium-gadolinium oxide is a promising material for electrolytes of intermediate temperature solid oxide fuel cells (IT-SOFCs) due to its high electrical conductivity at relatively lower temperatures of 400–700 °C. However, a high sintering temperature of up to 1550 °C is typically required to produce dense CGO electrolyte, eventually leading to an interfacial interdiffusion between the electrolyte and electrode components as well as generate a highly resistive interface which reduces ionic conductivity. Lowering the sintering temperature of the electrolyte will greatly benefit the fabrication of SOFCs. This study examines the effectiveness of introducing nano size CGO particles as an approach to get dense CGO electrolyte at lower sintering temperature. A series of dope suspensions with 0–50% nano size loading were prepared to observe rheology and measure viscosity. Then, 30% loading was selected and casting into flat sheet via phase-inversion technique. The flat sheet was characterized by morphology, surface roughness and mechanical strength tests. The suspension was extruded into dual-layer hollow fiber (DLHF) as well. The electrolyte/anode dual-layer hollow fibers (DLHFs) half-cell of micro-tubular solid oxide fuel cells (MT-SOFCs) were prepared via phase inversion based co-extrusion/co-sintering technique. The developed half-cell was characterized by morphological and gas tightness tests which further compared them with fully micron ones. The results show that the incorporation of 30% nanoparticle yielded to dense and tight CGO layers sintered at temperature 1450 °C, which about 50 °C lower than those reported previously for 100% micron particles. The I–V measurements demonstrated the maximum power density of 0.66 Wcm−2 at temperatures 500 °C using 100% H2 as fuel. Therefore, this approach is able to reduce the energy cost for the microstructural control of the prepared fiber and thus is recommended for the fabrication of low-cost dual-layer hollow fiber micro tubular SOFCs.