Abstract: A membrane for use in a high temperature gas processing system and method for making the same. The membrane includes a dense, gas impermeable layer and a first and second porous layer, wherein each of the first and second porous layers is a ceramic oxide material having a non-symmetrical load bearing skeleton of a plurality of pores having a graded porosity. Each porous layer provides a reduction of an oxygen partial pressure gradient across the dense layer and reduces resultant stresses in the dense layer that are small compared to its strength thereby improving long term mechanical durability of the dense layer.

Abstract: The invention is a novel solid oxide fuel cell (SOFC) stack comprising individual bi-electrode supported fuel cells in which an electrolyte layer is supported between porous electrodes. The porous electrodes may be made from graded pore ceramic tape that has been created by the freeze cast method followed by freeze-drying. Each piece of graded pore tape later becomes a graded pore electrode scaffold that, subsequent to sintering, is made into either an anode or a cathode. The electrode scaffold comprising the anode includes a layer of liquid metal. The pores of the electrode scaffolds gradually increase in diameter as the layer extends away from the electrolyte layer. As a result of this diameter increase, any forces that would tend to pull the liquid metal away from the electrolyte are reduced while maintaining a diffusion path for the fuel. Advantageously, the fuel cell of the invention may utilize a hydrocarbon fuel without pre-processing to remove sulfur.

Abstract: The invention is a novel solid oxide fuel cell (SOFC) stack comprising individual bi-electrode supported fuel cells in which a thin electrolyte is supported between electrodes of essentially equal thickness. Individual cell units are made from graded pore ceramic tape that has been created by the freeze cast method followed by freeze drying. Each piece of graded pore tape later becomes a graded pore electrode scaffold that subsequent to sintering, is made into either an anode or a cathode by means of appropriate solution and thermal treatment means. Each cell unit is assembled by depositing of a thin coating of ion conducting ceramic material upon the side of each of two pieces of tape surface having the smallest pore openings, and then mating the coated surfaces to create an unsintered electrode scaffold pair sandwiching an electrolyte layer.

Abstract: A membrane for use in a high temperature gas processing system and method for making the same. The membrane includes a dense, gas impermeable layer and a first and second porous layer, wherein each of the first and second porous layers is a ceramic oxide material having a non-symmetrical load bearing skeleton of a plurality of pores having a graded porosity. Each porous layer provides a reduction of an oxygen partial pressure gradient across the dense layer and reduces resultant stresses in the dense layer that are small compared to its strength thereby improving long term mechanical durability of the dense layer.

Abstract: The invention is a novel solid oxide fuel cell (SOFC) stack comprising individual bi-electrode supported fuel cells in which a thin electrolyte is supported between electrodes of essentially equal thickness. Individual cell units are made from graded pore ceramic tape that has been created by the freeze cast method followed by freeze drying. Each piece of graded pore tape later becomes a graded pore electrode scaffold that subsequent to sintering, is made into either an anode or a cathode by means of appropriate solution and thermal treatment means. Each cell unit is assembled by depositing of a thin coating of ion conducting ceramic material upon the side of each of two pieces of tape surface having the smallest pore openings, and then mating the coated surfaces to create an unsintered electrode scaffold pair sandwiching an electrolyte layer.

Abstract: A solid oxide fuel cell (SOFC) has a porous electrode support structure on both sides of a thin electrolyte layer. The porous electrode supported cell is formed with gas flow plenum channels on an outer surface of the electrode scaffold.

Abstract: The present invention is a symmetrical bi-electrode supported solid oxide fuel cell comprising a sintered monolithic framework having graded pore electrode scaffolds that, upon treatment with metal solutions and heat subsequent to sintering, acquire respective anodic and cathodic catalytic activity. The invention is also a method for making such a solid oxide fuel cell. The graded pore structure of the graded pore electrode scaffolds in achieved by a novel freeze casting for YSZ tape.

Abstract: Solid membranes comprising an intimate, gas-impervious, multi-phase mixture of an electronically-conductive material and an oxygen ion-conductive material and/or a mixed metal oxide of a perovskite structure are described. Electrochemical reactor components, such as reactor cells, and electrochemical reactors are also described for transporting oxygen from any oxygen-containing gas to any gas or mixture of gases that consume oxygen. The reactor cells generally comprise first and second zones separated by an element having a first surface capable of reducing oxygen to oxygen ions, a second surface capable of reacting oxygen ions with an oxygen-consuming gas, an electron-conductive path between the first and second surfaces and an oxygen ion-conductive path between the first and second surfaces. The element may further comprise (1) a porous substrate, (2) an electron-conductive metal, metal oxide or mixture thereof and/or (3) a catalyst.

Abstract: A method, apparatus and assembly related to solid oxide fuel cell interconnects is disclosed. In its broadest embodiment, the invention contemplates a multi-layered ceramic interconnect having integrated flow fields and electrical connections. The method of making this interconnect includes judicious selection of materials, formation of appropriate apertures for the flow fields and electrical connectors, and the joining of the layers through a firing and/or sealing process.

Abstract: A fuel cell having an anode and a cathode side with fuel flowing over the anode side and air over the cathode side has a staging plate located on the anode side of the fuel cell to divide the flow of fuel to two different sections of the anode. A second staging plate may be used to divide the flow of fuel to three different sections of the anode and various apertures may be formed in the plates, such as rectangles triangles or ovals, to direct fuel flow to desired areas of the anode.

Abstract: Solid membranes comprising an intimate, gas-impervious, multi-phase mixture of an electronically-conductive material and an oxygen ion-conductive material and/or a mixed metal oxide of a perovskite structure are described. Electrochemical reactor components, such as reactor cells, and electrochemical reactors are also described for transporting oxygen from any oxygen-containing gas to any gas or mixture of gases that consume oxygen. The reactor cells generally comprise first and second zones separated by an element having a first surface capable of reducing oxygen to oxygen ions, a second surface capable of reacting oxygen ions with an oxygen-consuming gas, an electron-conductive path between the first and second surfaces and an oxygen ion-conductive path between the first and second surfaces. The element may further comprise (1) a porous substrate, (2) an electron-conductive metal, metal oxide or mixture thereof and/or (3) a catalyst.

Abstract: A method, apparatus and assembly related to solid oxide fuel cell interconnects is disclosed. In its broadest embodiment, the invention contemplates a multi-layered ceramic interconnect having integrated flow fields and electrical connections. The method of making this interconnect includes judicious selection of materials, formation of appropriate apertures for the flow fields and electrical connectors, and the joining of the layers through a firing and/or sealing process.

Abstract: The invention relates to a process for the separation of oxygen from an oxygen-containing fluid using novel membranes, formed from perovskitic or multi-phase structures, with a chemically active coating. The process exhibits exceptionally high rates of oxygen flux. The process uses membranes that are conductors of oxygen ions and electrons, which are substantially stable in air over the temperature range of 25° C. to the operating temperature of the membrane.

Abstract: The invention relates to a process for the production of oxygen using novel membranes, formed from perovskitic or multi-phase structures, with a chemically active coating which demonstrate exceptionally high rates of fluid flux. The process uses membranes that are conductors of oxygen ions and electrons, which are substantially stable in air over the temperature range of 25° C. to the operating temperature of the membrane.

Abstract: A fuel cell having an anode and a cathode side with fuel flowing over the anode side and air over the cathode side has a staging plate located on the anode side of the fuel cell to divide the flow of fuel to two different sections of the anode. A second staging plate may be used to divide the flow of fuel to three different sections of the anode and various apertures may be formed in the plates, such as rectangles triangles or ovals, to direct fuel flow to desired areas of the anode.

Abstract: An exothermic reaction and an endothermic reaction are thermally combined in a reactor having at least one oxygen selective ion transport membrane that provides the exothermic reaction with oxygen from an oxygen-containing gas such as air. The thermal requirements of the endothermic reaction are satisfied by the exothermic reaction. Dependent on the reactor design employed, the exothermic and endothermic reactions may be gaseously combined.

Abstract: A fuel cell having an anode and a cathode side with fuel flowing over the anode side and air over the cathode side has a staging plate located on the anode side of the fuel cell to divide the flow of fuel to two different sections of the anode. A second staging plate may be used to divide the flow of fuel to three different sections of the anode and various apertures may be formed in the plates, such as rectangles triangles or ovals, to direct fuel flow to desired areas of the anode.

Abstract: Electrochemical processes using solid gas-impervious membranes are disclosed for gas cleanup by (A) providing an electrochemical cell comprising first and second zones separated by a solid gas-impervious membrane comprising a mixed metal oxide material of a perovskite structure having electron conductivity and oxygen ion conductivity, (B) passing a gas containing N2O, NO, NO2, SO2, SO3, or a mixture thereof, in contact with the membrane in the first zone, and (C) passing a gas capable of reacting with oxygen in contact with the membrane in the second zone. More particularly, the mixed metal oxide material of a perovskite structure comprises a combination of elements selected from the group consisting of lanthanides, alkaline earth metals, Y, Sc, Ti, V, Cr, Mn, Fe, Co, Ni, Cu, Zn, Zr, and Nb, oxides thereof, and mixtures of these metals and metal oxides. Advantageously a catalyst is present in the first zone.

Abstract: Solid membranes comprising an intimate, gas-impervious, multi-phase mixture of an electronically-conductive material and an oxygen ion-conductive material and/or a mixed metal oxide of a perovskite structure are described. Electrochemical reactor components, such as reactor cells, and electrochemical reactors are also described. The reactor cells generally comprise first and second zones separated by an element having a first surface capable of reducing oxygen to oxygen ions, a second surface capable of reacting oxygen ions with an oxygen-consuming gas, an electron-conductive path between the first and second surfaces and an oxygen ion-conductive path between the first and second surfaces.

Abstract: A process and apparatus for steam reforming of hydrocarbons, using a sulfur-tolerant catalyst comprising an active phase and a support phase, and optionally a promoter, which provides substantially complete conversion of the hydrocarbon to a mixture of hydrogen, carbon monoxide, and carbon dioxide. The process comprises introducing steam and a hydrocarbon feed containing at least about 2 ppm sulfur species into the apparatus, and reacting said steam and hydrocarbon feed in the catalyst bed.