Fuel cells convert chemical energy directly into electrical energy with high efficiency and low emission of pollutants. However, before fuel-cell technology can gain a significant share of the electrical power market, important issues have to be addressed. These issues include optimal choice of fuel, and the development of alternative materials in the fuel-cell stack. Present fuel-cell prototypes often use materials selected more than 25 years ago. Commercialization aspects, including cost and durability, have revealed inadequacies in some of these materials. Here we summarize recent progress in the search and development of innovative alternative materials.

Materials for fuel-cell technologies

A ceramic fuel cell in an all solid-state energy conversion device that produces electricity by electrochemically combining fuel and oxidant gases across an ionic conducting oxide. Current ceramic fuel cells use an oxygen-ion conductor or a proton conductor as the electrolyte and operate at high temperatures (>600°C). Ceramic fuel cells, commonly referred to as solid-oxide fuel cells (SOFCs), are presently under development for a variety of power generation applications. This paper reviews the science and technology of ceramic fuel cells and discusses the critical issues posed by the development of this type of fuel cell. The emphasis is given to the discussion of component materials (especially, ZrO2 electrolyte, nickel/ZrO2 cermet anode, LaMnO3 cathode, and LaCrO3 interconnect), gas reactions at the electrodes, stack designs, and processing techniques used in the fabrication of required ceramic structures.

Ceramic Fuel Cells

Ionically conducting polymer membranes (polymer electrolytes) might enhance lithium-battery technology by replacing the liquid electrolyte currently in use and thereby enabling the fabrication of flexible, compact, laminated solid-state structures free from leaks and available in varied geometries1. Polymer electrolytes explored for these purposes are commonly complexes of a lithium salt (LiX) with a high-molecular-weight polymer such as polyethylene oxide (PEO). But PEO tends to crystallize below 60 °C, whereas fast ion transport is a characteristic of the amorphous phase. So the conductivity of PEO–LiX electrolytes reaches practically useful values (of about 10−4 S cm−1) only at temperatures of 60–80 °C. The most common approach for lowering the operational temperature has been to add liquid plasticizers, but this promotes deterioration of the electrolyte's mechanical properties and increases its reactivity towards the lithium metal anode. Here we show that nanometre-sized ceramic powders can perform as solid plasticizers for PEO, kinetically inhibiting crystallization on annealing from the amorphous state above 60 °C. We demonstrate conductivities of around 10−4 S cm−1 at 50 °C and 10−5 S cm−1 at 30 °C in a PEO–LiClO4 mixture containing powders of TiO2 and Al2O3 with particle sizes of 5.8–13 nm. Further optimization might lead to practical solid-state polymer electrolytes for lithium batteries.

Nanocomposite polymer electrolytes for lithium batteries

Fuel cells directly and efficiently convert chemical energy to electrical energy. Of the various fuel cell types, solid-oxide fuel cells (SOFCs) combine the benefits of environmentally benign power generation with fuel flexibility. However, the necessity for high operating temperatures (800–1,000 °C) has resulted in high costs and materials compatibility challenges. As a consequence, significant effort has been devoted to the development of intermediate-temperature (500–700 °C) SOFCs. A key obstacle to reduced-temperature operation of SOFCs is the poor activity of traditional cathode materials for electrochemical reduction of oxygen in this temperature regime2. Here we present Ba_(0.5_Sr_(0.5)Co_(0.8)Fe_(0.2)O_(3-delta) (BSCF) as a new cathode material for reduced-temperature SOFC operation. BSCF, incorporated into a thin-film doped ceria fuel cell, exhibits high power densities (1,010 mW cm^(-2) and 402 mW cm^(-2) at 600 °C and 500 °C, respectively) when operated with humidified hydrogen as the fuel and air as the cathode gas. We further demonstrate that BSCF is ideally suited to 'single-chamber' fuel-cell operation, where anode and cathode reactions take place within the same physical chamber. The high power output of BSCF cathodes results from the high rate of oxygen diffusion through the material. By enabling operation at reduced temperatures, BSCF cathodes may result in widespread practical implementation of SOFCs.

A high-performance cathode for the next generation of solid-oxide fuel cells

Recent worldwide interest in building a decentralized, hydrogen-based energy economy has refocused attention on the solid oxide fuel cell (SOFC) as a potential source of efficient, environmentally friendly, fuel-versatile electric power. Due to its high operating temperature, the SOFC offers several potential advantages over polymer-based fuel cells, including reversible electrode reactions, low internal resistance, high tolerance to typical catalyst poisons, production of high-quality waste heat for (among other uses) reformation of hydrocarbon fuels, as well as the possibility of burning hydrocarbon fuels directly. Today, SOFCs are much closer to commercial reality than they were 20 years ago, due largely to technological advances in electrode material composition, microstructure control, thin-film ceramic fabrication, and stack and system design. These advances have led to dozens of active SOFC development programs in both stationary and mobile power and contributed to commercialization or development in a number of related technologies, including gas sensors,1 solid-state electrolysis devices,2 and iontransport membranes for gas separation and partial oxidation.3 Many reviews are available which summarize the technological advances made in SOFCs over the last 15-35 yearssreaders who are primarily interested in knowing the state-of-the art in materials, design, and fabrication (including the electrodes) are encouraged to consult these reviews.4-12 This review focuses on the factors governing SOFC cathode performancesadvances we have made over † Dedicated to Brian Steele, 1929-2003. Researcher, Entrepreneur, Consensus Seeker. 4791 Chem. Rev. 2004, 104, 4791−4843

Factors Governing Oxygen Reduction in Solid Oxide Fuel Cell Cathodes

Appraisal of Ce1−yGdyO2−y/2 electrolytes for IT-SOFC operation at 500°C

Effects of inert fillers on the mechanical and electrochemical properties of lithium salt-poly(ethylene oxide) polymer electrolytes

Materials for IT-SOFC stacks: 35 years R&D: the inevitability of gradualness?

Interfacial reactions associated with ceramic ion transport membranes

Properties of La0.6Sr0.4Co0.2Fe0.8O3-x (LSCF) double layer cathodes on gadolinium-doped cerium oxide (CGO) electrolytes - II. Role of oxygen exchange and diffusion

B.C.H. Steele

Papers

Appraisal of Ce1−yGdyO2−y/2 electrolytes for IT-SOFC operation at 500°C

Effects of inert fillers on the mechanical and electrochemical properties of lithium salt-poly(ethylene oxide) polymer electrolytes

Materials for IT-SOFC stacks: 35 years R&D: the inevitability of gradualness?

Interfacial reactions associated with ceramic ion transport membranes

Properties of La0.6Sr0.4Co0.2Fe0.8O3-x (LSCF) double layer cathodes on gadolinium-doped cerium oxide (CGO) electrolytes - II. Role of oxygen exchange and diffusion