Fabrication of high-quality electrode films for solid oxide fuel cell by screen printing: A review on important processing parameters
Corresponding Author
Nurul Akidah Baharuddin
Fuel Cell Institute, Universiti Kebangsaan Malaysia, Bangi, Malaysia
Correspondence
Nurul Akidah Baharuddin, Fuel Cell Institute, Universiti Kebangsaan Malaysia, 43600 UKM, Bangi, Selangor, Malaysia.
Email: [email protected]
Search for more papers by this authorNurul Farhana Abdul Rahman
Faculty of Mechanical and Manufacturing Engineering, Universiti Tun Hussein Onn Malaysia, Batu Pahat, Malaysia
Search for more papers by this authorHamimah Abd. Rahman
Faculty of Mechanical and Manufacturing Engineering, Universiti Tun Hussein Onn Malaysia, Batu Pahat, Malaysia
Search for more papers by this authorMahendra Rao Somalu
Fuel Cell Institute, Universiti Kebangsaan Malaysia, Bangi, Malaysia
Search for more papers by this authorMohd Azham Azmi
Faculty of Mechanical and Manufacturing Engineering, Universiti Tun Hussein Onn Malaysia, Batu Pahat, Malaysia
Search for more papers by this authorJarot Raharjo
Agency for the Assessment and Application of Technology, Center for Materials Technology, South Tangerang, Indonesia
Search for more papers by this authorCorresponding Author
Nurul Akidah Baharuddin
Fuel Cell Institute, Universiti Kebangsaan Malaysia, Bangi, Malaysia
Correspondence
Nurul Akidah Baharuddin, Fuel Cell Institute, Universiti Kebangsaan Malaysia, 43600 UKM, Bangi, Selangor, Malaysia.
Email: [email protected]
Search for more papers by this authorNurul Farhana Abdul Rahman
Faculty of Mechanical and Manufacturing Engineering, Universiti Tun Hussein Onn Malaysia, Batu Pahat, Malaysia
Search for more papers by this authorHamimah Abd. Rahman
Faculty of Mechanical and Manufacturing Engineering, Universiti Tun Hussein Onn Malaysia, Batu Pahat, Malaysia
Search for more papers by this authorMahendra Rao Somalu
Fuel Cell Institute, Universiti Kebangsaan Malaysia, Bangi, Malaysia
Search for more papers by this authorMohd Azham Azmi
Faculty of Mechanical and Manufacturing Engineering, Universiti Tun Hussein Onn Malaysia, Batu Pahat, Malaysia
Search for more papers by this authorJarot Raharjo
Agency for the Assessment and Application of Technology, Center for Materials Technology, South Tangerang, Indonesia
Search for more papers by this authorAbbreviations: AC, activated carbon; APU, auxiliary power unit; ASR, area-specific resistance; DMFC, direct methanol fuel cell; EC, ethyl cellulose; EG, ethylene glycol; GDL, gas diffusion layer; LSC, La0.6Sr0.4CoO3−δ; LSM, lanthanum strontium magnetite; MCFC, molten carbonate fuel cell; MFC, microbial fuel cell; Ni, nickel; NiO, nickel oxide; OCV, open-circuit voltage; PAFC, phosphoric acid fuel cell; PEMFC, proton exchange membrane fuel cell; ScSZ, scandia-stabilised zirconia; SDC, samarium-doped ceria; SEM, scanning electron microscopy; SOFC, solid oxide fuel cell; YSZ, yttria-stabilised zirconia.
Funding information: Universiti Kebangsaan Malaysia, Grant/Award Number: Grant No.: DIP-2019-011; Universiti Tun Hussein Onn Malaysia, Grant/Award Number: GPPS H577
Summary
Solid oxide fuel cell (SOFC) is known as the most efficient fuel cell, with an efficiency of 60% in converting fuel to electricity and up to 80% in fuel to energy conversion (including heat). A SOFC consists of three primary components, namely, anode, electrolyte and cathode. Given the demand for reducing the operating temperature below 800°C, not only thin electrolytes have become a necessity for their ability to reduce ohmic losses but also high-quality porous electrode (anode and cathode) films for their ability to accelerate electrochemical reactions with fuels. In this context, screen printing is known for its capability to form high-quality porous electrode films in a cost-effective manner. In addition, screen printing offers fabrication-related parameters that can be easily manipulated to produce different film qualities depending on the requirements which have been explored in various applications. However, screen printing is only utilised in SOFC application as a fabrication tool to produce electrode films, neglecting the effects of its fabrication-related parameters on electrode performance, as indicated by the limited number of related works. Despite limited resources, this study aims to review the fabrication-related parameters in producing SOFC electrodes through screen printing and their effects on electrochemical performance. The parameters at different stages (ie, prior, during and post printing), including ink formation, printing numbers and sintering, are extensively reviewed. To the best of our knowledge, this study is not only the first review that discusses the effects of screen-printing fabrication-related parameters on electrode potentials but also offers suggestions on future directions regarding these parameters towards the improvement of SOFC performance.
Novelty Statement
Among all thin-film fabrication methods, screen printing is known for its capability to form homogenous-porous SOFC electrode films; however, the processing parameters of screen printing at three primary stages (prior, during, and postprinting) are rarely explored. As such, the current paper highlights important parameters in screen printing, such as ink rheology, printing number, and sintering, to contribute to the understanding of the influence of these parameters on SOFC electrode film quality and their effects on electrochemical performance.
REFERENCES
- 1Tarancón A. Strategies for lowering solid oxide fuel cells operating temperature. Energies. 2009; 2(4): 1130-1150.
- 2Sharaf OZ, Orhan MF. An overview of fuel cell technology: fundamentals and applications. Renewable Sustainable Energy Rev. 2014; 32: 810-853.
- 3Vielstich W, Lamm A, Gasteiger HA. In: HA Gasteiger, ed. Handbook of Fuel Cells: Fundamentals, Technology, and Applications. Vol 2. United Kingdom: John Wiley & Sons Ltd; 2007.
- 4Dicks AL, Rand DAJ. Fuel Cell Systems Explained. 3rd ed.United Kingdom: John Wiley & Sons Ltd; 2018.
10.1002/9781118706992 Google Scholar
- 5Sudhakar YN, Selvakumar M, Bhat DK, eds. Biopolymer electrolytes for fuel cell applications. Biopolymer Electrolytes. Netherlands: Elsevier; 2018: 151-166.
10.1016/B978-0-12-813447-4.00005-4 Google Scholar
- 6Behling NH, ed. History of phosphoric acid fuel cells. Fuel Cells. Netherlands: Elsevier; 2013: 53-135.
10.1016/B978-0-444-56325-5.00004-1 Google Scholar
- 7Lanzini A, Madi H, Chiodo V, et al. Dealing with fuel contaminants in biogas-fed solid oxide fuel cell (SOFC) and molten carbonate fuel cell (MCFC) plants: degradation of catalytic and electro-catalytic active surfaces and related gas purification methods. Prog Energy Combust Sci. 2017; 61: 150-188.
- 8Williams MC, Strakey JP, Surdoval WA. The U.S. Department of Energy, Office of Fossil Energy Stationary Fuel Cell Program. J Power Sources. 2005; 143: 191-196.
- 9Mehmeti A, Santoni F, Della Pietra M, McPhail SJ. Life cycle assessment of molten carbonate fuel cells: state of the art and strategies for the future. J Power Sources. 2016; 308: 97-108.
- 10Antolini E. The stability of molten carbonate fuel cell electrodes: a review of recent improvements. Appl Energy. 2011; 88(12): 4274-4293.
- 11Weber AZ, Lipman TE. Fuel cells and hydrogen production: introduction. In: TE Lipman, AZ Weber, eds. Fuel Cells and Hydrogen Production: A Volume in the Encyclopedia of Sustainability Science and Technology. 2nd ed.New York: Springer; 2019: 1-8.
10.1007/978-1-4939-7789-5_1051 Google Scholar
- 12Lanzini A, Leone P, Asinari P. Microstructural characterization of solid oxide fuel cell electrodes by image analysis technique. J Power Sources. 2009; 194(1): 408-422.
- 13Mahato N, Banerjee A, Gupta A, Omar S, Balani K. Progress in material selection for solid oxide fuel cell technology: a review. Prog Mater Sci. 2015; 72: 141-337.
- 14Medvedev DA, Lyagaeva JG, Gorbova EV, Demin AK, Tsiakaras P. Advanced materials for SOFC application: strategies for the development of highly conductive and stable solid oxide proton electrolytes. Prog Mater Sci. 2016; 75: 38-79.
- 15Ramadhani F, Hussain MA, Mokhlis H, Hajimolana S. Optimization strategies for Solid Oxide Fuel Cell ( SOFC ) application: a literature survey. Renewable Sustainable Energy Rev. 2017; 76: 460-484.
- 16Ud Din Z, Zainal ZA. The fate of SOFC anodes under biomass producer gas contaminants. Renewable Sustainable Energy Rev. 2017; 72: 1050-1066.
- 17Brodnikovskyi Y, McDonald N, Polishko I, et al. Properties of 10Sc1CeSZ-3.5YSZ(33-, 40-, 50-wt.%) composite ceramics for SOFC application. Mater Today Proc. 2019; 6: 26-35.
- 18Baharuddin NA, Muchtar A, Somalu MR. Short review on cobalt-free cathodes for solid oxide fuel cells. Int J Hydrogen Energy. 2017; 42(14): 9149-9155.
- 19Rashid NLRM, Samat AA, Jais AA, et al. Review on zirconate-cerate-based electrolytes for proton-conducting solid oxide fuel cell. Ceram Int. 2019; 45(6): 6605-6615.
- 20Zakaria Z, Hasmady S, Hassan A, Shaari N. A review on recent status and challenges of yttria stabilized zirconia modification to lowering the temperature of solid oxide fuel cells operation. Int J Energy Res. 2019; 44(2): 594-611.
- 21Colpan CO, Nalbant Y, Ercelik M. Fundamentals of fuel cell technologies. In: I Dincer, ed. Comprehensive Energy Systems. Vol 4. Netherlands: Elsevier; 2018: 5540.
10.1016/B978-0-12-809597-3.00446-6 Google Scholar
- 22Jiang SP. Nanoscale and nano-structured electrodes of solid oxide fuel cells by infiltration: advances and challenges. Int J Hydrogen Energy. 2012; 37: 449-470.
- 23Mekhilef S, Saidur R, Safari A. Comparative study of different fuel cell technologies. Renewable Sustainable Energy Rev. 2012; 16(1): 981-989.
- 24Kim KH, Park YM, Kim H. Fabrication and evaluation of the thin NiFe supported solid oxide fuel cell by co-firing method. Energy. 2010; 35(12): 5385-5390.
- 25Ud Z, Zainal ZA. Biomass integrated gasification – SOFC systems: technology overview. Renewable Sustainable Energy Rev. 2016; 53: 1356-1376.
- 26Adler SB. Factors governing oxygen reduction in solid oxide fuel cell cathodes. Chem Rev. 2004; 104(10): 4791-4844.
- 27Blum L, Steinberger-wilckens R. SOFC worldwide - Technology development status and early applications. Paper presented at: Fuel Cell Technologies: State and Perspectives: Proceedings of the NATO Advanced Research Workshop on Fuel Cell Technologies: State and Perspectives; June 6-10 2004; Kyiv, Ukraine: 107-122.
- 28Kothiyal GP, Ananthanarayanan A, Dey GK. Glass and glass-ceramics. In: S Banerjee, AK Tyagi, eds. Functional Materials. Netherlands: Elsevier; 2012: 323-386.
10.1016/B978-0-12-385142-0.00009-X Google Scholar
- 29Fergus JW, Hui R, Li X, Wilkinson DP, Zhang J. Solid Oxide Fuel Cells Materials Properties and Performance. New York: CRC Press; 2009.
- 30Tan KH, Rahman HA, Taib H. Coating layer and influence of transition metal for ferritic stainless steel interconnector solid oxide fuel cell: a review. Int J Hydrogen Energy. 2019; 44: 30591-30605.
- 31Entchev E. Residential fuel cell energy systems performance optimization using “soft computing” techniques. J Power Sources. 2003; 118: 212-217.
- 32Burer M, Tanaka K, Favrat D, Yamada K. Multi-criteria optimization of a district cogeneration plant integrating a solid oxide fuel cell – gas turbine combined cycle , heat pumps and chillers. Energy. 2003; 28: 497-518.
- 33Tikiz I, Taymaz I. An experimental investigation of solid oxide fuel cell performance at variable operating conditions. Therm Sci. 2016; 20(5): 1421-1433.
- 34Sadeghi M, Chitsaz A, Mahmoudi SMS, Rosen MA. Thermoeconomic optimization using an evolutionary algorithm of a trigeneration system driven by a solid oxide fuel cell. Energy. 2015; 89: 191-204.
- 35Hassmann K. SOFC power plants, the Siemens-Westinghouse approach. Fuel Cells. 2001; 1(1): 78-84.
- 36Irvine JTS, Connor P. Solid Oxide Fuels Cells: Facts and Figures. London: Springer; 2013.
10.1007/978-1-4471-4456-4 Google Scholar
- 37Zhu B. Solid oxide fuel cell (SOFC) technical challenges and solutions from nano-aspects. Int J Energy Res. 2009; 33: 1126-1137.
- 38Baharuddin NA, Muchtar A, Somalu MR, Kalib NS, Raduwan NF. Synthesis and characterization of SrFe0.8Ti0.2O3-δ cobalt-free through combustion method for solid oxide fuel cells. Int J Hydrogen Energy. 2019; 44: 30682-30691.
- 39Abdalla AM, Hossain S, Azad AT, Petra PMI. Nanomaterials for solid oxide fuel cells: a review. Renewable Sustainable Energy Rev. 2018; 82(August 2017): 353-368.
- 40Sari D, Piskin F, Torunoglu ZC, Yasar B, Kalay YE. Combinatorial development of nanocrystalline/amorphous (La,Sr)CoO3-(La,Sr)2CoO4 composite cathodes for IT-SOFCs. Solid State Ion. 2018; 326: 124-130.
- 41Huang QA, Oberste-Berghaus J, Yang D, et al. Polarization analysis for metal-supported SOFCs from different fabrication processes. J Power Sources. 2008; 177(2): 339-347.
- 42Han D, Liu J, He YB, Wang HF, Zhang XZ, Wang SR. Fabrication of a quasi-symmetrical solid oxide fuel cell using a modified tape casting/screen-printing/infiltrating combined technique. Int J Hydrogen Energy. 2018; 43(2): 960-967.
- 43Song JH, Park SI, Lee JH, Kim HS. Fabrication characteristics of an anode-supported thin-film electrolyte fabricated by the tape casting method for IT-SOFC. J Mater Process Technol. 2008; 198(1–3): 414-418.
- 44Kim SD, Lee JJ, Moon H, et al. Effects of anode and electrolyte microstructures on performance of solid oxide fuel cells. J Power Sources. 2007; 169(2): 265-270.
- 45Xia C, Liu M. Low-temperature SOFCs based on Gd0.1Ce0.9O1.95 fabricated by dry pressing. Solid State Ion. 2001; 144(3–4): 249-255.
- 46Basu RN, Randall CA, Mayo MJ. Fabrication of dense zirconia electrolyte films for tubular solid oxide fuel cells by electrophoretic deposition. J Am Ceram Soc. 2001; 84(1): 33-40.
- 47Borojeni A et al. Fabrication of solid oxide fuel cells (SOFCs) electrolytes by electrophoretic deposition (EPD) and optimizing the process. Key Eng Mater. 2015; 654: 83-87.
10.4028/www.scientific.net/KEM.654.83 Google Scholar
- 48Hart N, Brandon N, Shemilt J. Environmental evaluation of thick film ceramic fabrication techniques for solid oxide fuel cells. Mater Manuf Process. 2000; 15(1): 47-64.
- 49Billemar J. How Anode Porosity Affects the Performance of a Solid Oxide Fuel Cell. Sweden: Chalmers University of Technology; 2014.
- 50Anwar M, Ali SAM, Baharuddin NA, Raduwan NF, Muchtar A, Somalu MR. Structural, optical and electrical properties of Ce0.8Sm0.2-xErxO2-δ (x=0–0.2) Co-doped ceria electrolytes. Ceram Int. 2018; 44(12): 13639-13648.
- 51Somalu MR, Muchtar A, Daud WRW, Brandon NP. Screen-printing inks for the fabrication of solid oxide fuel cell films: a review. Renewable Sustainable Energy Rev. 2017; 75: 426-439.
- 52Somalu MR, Brandon NP. Rheological studies of nickel/scandia-stabilized-zirconia screen printing inks for solid oxide fuel cell anode fabrication. J Am Ceram Soc. 2012; 95(4): 1220-1228.
- 53Samat AA, Somalu MR, Muchtar A. Optimisation of screen-printed La0.6Sr0.4CoO3-δ cathode film for intermediate temperature proton-conducting solid oxide fuel cell application for intermediate temperature proton-conducting solid oxide fuel cell application. IOP Conf Ser. 2019; 268: 1-6.
- 54Larminie J, Dicks A, J Larminie, A Dicks. Fuel Cell Systems Explained. 2nd ed. United Kingdom: John Wiley & Sons Ltd; 2003: 14-16.
10.1002/9781118878330 Google Scholar
- 55Wan Yusoff WNA, Norman NW, Abdul Samat A, Somalu MR, Muchtar A, Baharuddin NA. Fabrication process of cathode materials for solid oxide fuel. J Adv Res Fluid Mech Therm Sci. 2018; 50(2): 153-160.
- 56Sadykov V, Usoltsev V, Fedorova Y, et al. Advanced sintering techniques in design of planar IT SOFC and supported oxygen separation membranes. In: A Lakshmanan, ed. Sintering of Ceramics - New Emerging Techniques. United Kingdom: IntechOpen; 2012: 610.
10.5772/34958 Google Scholar
- 57Mahmud LS, Muchtar A, Somalu MR. Challenges in fabricating planar solid oxide fuel cells: a review. Renewable Sustainable Energy Rev. 2017; 72: 105-116.
- 58Pijolat C. Screen-printing for the fabrication of solid oxide fuel cells (SOFC). In: P Prudenziati, J Hormadaly, eds. Printed Films: Materials Science and Applications in Sensors, Electronics and Photonics. United Kingdom: Woodhead Publishing Limited; 2012: 469-495.
10.1533/9780857096210.2.469 Google Scholar
- 59Rotureau D, Viricelle JP, Pijolat C, Caillol N, Pijolat M. Development of a planar SOFC device using screen-printing technology. J Eur Ceram Soc. 2005; 25: 2633-2636.
- 60Wang Y, Leung DYC, Xuan J, Wang H. A review on unitized regenerative fuel cell technologies , part-A: unitized regenerative proton exchange membrane fuel cells. Renewable Sustainable Energy Rev. 2016; 65: 961-977.
- 61Somalu MR, Yufit V, Brandon NP. The effect of solids loading on the screen-printing and properties of nickel/scandia-stabilized-zirconia anodes for solid oxide fuel cells. Int J Hydrogen Energy. 2013; 38: 9500-9510.
- 62Somalu MR, Muchtar A, Brandon NP. Understanding the rheology of screen-printing inks for the fabrication of SOFC thick films. ECS Trans. 2015; 68(1): 1323-1331.
- 63Piao J, Sun K, Zhang N, Xu S. A study of process parameters of LSM and LSM-YSZ composite cathode films prepared by screen-printing. J Power Sources. 2008; 175: 288-295.
- 64Phair JW. Rheological analysis of concentrated zirconia pastes with ethyl cellulose for screen printing SOFC electrolyte films. J Am Ceram Soc. 2008; 91(7): 2130-2137.
- 65Carrijo MMM, Lorenz H, Rambo CR, Greil P, Travitzky N. Fabrication of Ti3SiC2-based pastes for screen printing on paper-derived Al2O3 substrates. Ceram Int. 2018; 44(7): 8116-8124.
- 66Sanson A, Roncari E, Boldrini S, Mangifesta P, Doubova L. Eco-friendly screen-printing inks of gadolinia doped ceria. J Fuel Cell Sci Technol. 2010; 7(5):0510131.
10.1115/1.3120271 Google Scholar
- 67Samat AA, Anasuhah WN, Yusoff W, et al. Electrochemical performance of sol-gel derived La0.6Sr0.4CoO3-δ cathode material for proton-conducting fuel cell: a comparison between simple and advanced cell fabrication techniques. Process Appl Ceram. 2018; 12(3): 277-286.
- 68Wang Z, Huang X, Lv Z, et al. Preparation and performance of solid oxide fuel cells with YSZ/SDC bilayer electrolyte. Ceram Int. 2015; 41(3): 4410-4415.
- 69Rolle A, Mohamed HAA, Huo D, et al. Ca3Co4O9+δ, a growing potential SOFC cathode material: impact of the layer composition and thickness on the electrochemical properties. Solid State Ion. 2016; 294: 21-30.
- 70Baharuddin NA, Somalu MR, Anwar M, et al. Effects of sintering temperature on the structural and electrochemical properties of SrFe0.5Ti0.5O3-δ perovskite cathode. Int J Appl Ceram Technol. 2018; 15: 338-348.
- 71Chang C-L, Hwang B-H. Microstructure and electrochemical characterization of Sm0.5Sr0.5CoO3 films as SOFC cathode prepared by the electrostatic-assisted ultrasonic spray pyrolysis method. Int J Appl Ceram Technol. 2008; 5(6): 582-588.
- 72Liu M, Lynch ME, Blinn K, Alamgir FM, Choi Y. Rational SOFC material design: new advances and tools. Mater Today. 2011; 14(11): 534-546.
- 73Singhal SC. Advances in solid oxide fuel cell technology. Solid State Ion. 2000; 135(1–4): 305-313.
- 74Ni C, Cassidy M, Irvine JTS. Image analysis of the porous yttria-stabilized zirconia (YSZ) structure for a lanthanum ferrite-impregnated solid oxide fuel cell (SOFC) electrode. J Eur Ceram Soc. 2018; 38(16): 5463-5470.
- 75Carpanese MP, Giuliano A, Panizza M, et al. Experimental approach for the study of SOFC cathodes. Bulg Chem Commun. 2016; 48(Special Issue B): 23-29.
- 76Ge X, Huang X, Zhang Y, et al. Screen-printed thin YSZ films used as electrolytes for solid oxide fuel cells. J Power Sources. 2006; 159(2): 1048-1050.
- 77Ried P, Lorenz C, Brönstrup A, et al. Processing of YSZ screen printing pastes and the characterization of the electrolyte layers for anode supported SOFC. J Eur Ceram Soc. 2008; 28(9): 1801-1808.
