High Entropy Alloy Anode for SOFC Carbon Deposition

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Solution Overview

Problem

Solid Oxide Fuel Cells (SOFCs) face issues with mechanical failure due to thermal stresses and carbon deposition when using Nickel-Yttria Stabilized Zirconia (Ni-YSZ) anodes, which are prone to coking and sulfur contamination, limiting fuel choice and stability.

Innovation Solution

A High Entropy Alloy (HEA) anode composed of Cobalt (Co), Copper (Cu), Iron (Fe), Manganese (Mn), and Nickel (Ni) is used, forming a cermet with Yttria Stabilized Zirconia (YSZ) to replace Ni-YSZ, enhancing stability and preventing carbon deposition while maintaining electrochemical reactivity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If Ni-YSZ anode is used, then electrochemical reactivity is maintained, but mechanical failure occurs due to thermal stresses and carbon deposition

Engineering Contradiction:

Improveanode stabilityVSAvoidcarbon deposition and thermal stresses

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent employs a composite High Entropy Alloy (HEA) consisting of five principal elements (Co, Cu, Fe, Mn, Ni) combined with Yttria Stabilized Zirconia (YSZ). This composite structure leverages the synergistic effects of multiple metals to achieve both high electrochemical reactivity and resistance to carbon deposition, while the YSZ component provides mechanical stability and thermal stress resistance.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent fundamentally changes the compositional parameters of the anode material by transitioning from conventional Ni-YSZ to a five-element HEA-YSZ composite. Specifically, it adjusts the atomic percentages of Co (20-30%), Cu (20-30%), Fe (20-30%), Mn (8-13%), and Ni (10-20%) to optimize both reactivity and stability, thereby resolving the contradiction between maintaining electrochemical performance and preventing carbon deposition.

Inventive Principle:

Principle #35Parameter changes

2Adaptability or versatility

If Ni-YSZ anode is used, then fuel adaptability is limited, but broader fuel choice is needed

Engineering Contradiction:

Improvefuel choiceVSAvoidanode stability

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The High Entropy Alloy anode is designed with multi-functional capabilities: it can reform various hydrocarbons (methane, ethane, propane), tolerate sulfur contamination, maintain structural stability at elevated temperatures, and exhibit high electrochemical reactivity. This universal performance across multiple fuel types and harsh conditions directly addresses the need for broader fuel adaptability without sacrificing reliability.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If conventional anode materials are used, then manufacturing is simpler, but performance and stability are compromised

Engineering Contradiction:

Improveanode stabilityVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent specifies precise compositional parameters for the HEA-YSZ anode: Co (20-30%), Cu (20-30%), Fe (20-30%), Mn (8-13%), and Ni (10-20%) in atomic percentages. These controlled parameter ranges enable reproducible manufacturing while achieving superior stability and performance, balancing manufacturing feasibility with enhanced anode reliability.

Inventive Principle:

Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The HEA-YSZ anode reduces reformation rates, avoids subcooling and carbon deposition, and maintains stability at elevated temperatures, improving the durability and efficiency of SOFCs by suppressing intermetallic phase formation and thermal stresses.

Implementation Method 1

High Entropy Alloy (HEA) anode... suppressing intermetallic phase formation... maintains stability at elevated temperatures

Methodology Applied

Scientific EffectConfigurational entropy:

Implementation Method 2

enhancing stability and preventing carbon deposition... reduces reformation rates, avoids subcooling and carbon deposition

Methodology Applied

Scientific EffectCatalysis: Catalysis

Data Source

PatentUS20220246947A1High entropy alloy (HEA) anode for solid oxide fuel cell (SOFC)

Publication Date: 2022.08.04 BLUEHALO LLC

AI summary

A High Entropy Alloy (HEA) anode for a Solid Oxide Fuel Cell (SOFC), in which the HEA anode comprises: approximately ten (˜10) atomic percent (%) to ˜35% Copper (Cu) (preferably ˜23% to ˜27% Cu, and more preferably ˜24% to ˜26% Cu); ˜10% to ˜35% Iron (Fe) (preferably ˜23% to ˜27% Fe, and more preferably ˜24% to ˜26% Fe); ˜10% to ˜35% Cobalt (Co) (preferably ˜23% to ˜27% Co, and more preferably ˜24% to ˜26% Co); ˜5% to ˜25% Nickel (Ni) (preferably ˜13% to ˜17% Ni, and more preferably ˜14% to ˜16% Ni); ˜5% to ˜20% Manganese (Mn) (preferably ˜8% to 13% Mn, and more preferably ˜9% to 11% Mn); and less than a total of ˜2% other elements as impurities (preferably less than ˜1% total of other elements or impurities, and more preferably less than ˜0.5% total of other elements or impurities), with the sum of all of the alloying elements (Cu, Fe, Co, Ni, Mn, and impurities or other elements) totaling 100%.