Molten Carbonate Fuel Cell Anode Creep Resistance via Reinforcing Layer

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Solution Overview

Problem

Conventional methods for manufacturing anodes for molten carbonate fuel cells face challenges in producing large-sized anodes with improved high-temperature creep resistance and long-term stability at reduced production costs, as they often require complex processes and heat treatment, leading to increased costs and potential material property deterioration.

Innovation Solution

A method involving the fabrication of an anode green sheet followed by lamination with a reinforcing layer, such as nickel or stainless steel, without heat treatment, to enhance mechanical stability and prevent sintering and creep phenomena, using alloys like Ni-Al and optimizing the composition and structure for improved high-temperature strength and creep resistance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional methods are used to manufacture anodes for molten carbonate fuel cells, then the anodes can be produced, but they suffer from sintering and creep at high temperatures leading to poor long-term stability

Engineering Contradiction:

Improvelong-term stabilityVSAvoidhigh-temperature creep resistance

Core Design Contradiction:

ReliabilityVSTemperature

Solution Approach 1:

The patent applies composite materials by combining porous nickel particles with alumina particles to create an anode that resists sintering and creep at high temperatures. The alumina forms a stable framework that prevents nickel particle aggregation, maintaining structural integrity and long-term stability during fuel cell operation.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent changes the material parameters by controlling the particle size distribution, pore structure, and compositional ratios of nickel and alumina. These parameter optimizations enable the anode to maintain its mechanical properties and electrochemical performance at operating temperatures of 650°C or higher.

Inventive Principle:

Principle #35Parameter changes

2Strength

If heat treatment processes are used to improve anode properties, then the high-temperature strength may be improved, but the production costs increase and material properties may deteriorate

Engineering Contradiction:

Improvehigh-temperature strengthVSAvoidproduction cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent applies preliminary action by pre-forming the anode green sheet with the desired porous structure and compositional distribution before sintering. The alumina is pre-distributed within the nickel matrix in the green sheet, so that during subsequent low-temperature processing, the final anode achieves high-temperature strength without requiring complex post-manufacturing heat treatments.

Inventive Principle:

Principle #10Preliminary action

3Reliability

If porous structures are used to increase reactive area, then the electrochemical activity is improved, but sintering and creep occur more easily at high temperatures

Engineering Contradiction:

Improvereactive areaVSAvoidpore distribution stability

Core Design Contradiction:

ReliabilityVSStability of the object's composition

Solution Approach 1:

The patent uses composite materials where alumina particles form a stable skeletal framework that maintains the porous structure's geometry at high temperatures. This framework prevents pore collapse and nickel particle migration, preserving both the reactive surface area and the pore distribution stability during long-term fuel cell operation.

Inventive Principle:

Principle #40Composite materials

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

This approach enables the production of large-sized anodes with enhanced long-term stability and reduced production costs by eliminating heat treatment, thereby improving the performance and lifespan of molten carbonate fuel cells.

Implementation Method 1

laminating the anode green sheet with a reinforcing layer through hot roll press or hot uniaxial press process

Methodology Applied

Scientific EffectHot roll press process:

Implementation Method 2

laminating the anode green sheet with a reinforcing layer through hot roll press or hot uniaxial press process

Methodology Applied

Scientific EffectHot uniaxial press process:

Implementation Method 3

mixing metal powder, a solvent, a dispersant, a binder, a plasticizer and a defoamer and then ball-milling the mixture to prepare an anode slurry for in-situ sintering

Methodology Applied

Scientific EffectBall-milling:

Implementation Method 4

forming the anode slurry for in-situ sintering to fabricate an anode green sheet

Methodology Applied

Scientific EffectTape casting:

Data Source

PatentUS8633122B2Method of manufacturing anode for in-situ sintering for molten carbonate fuel cell

Publication Date: 2014.01.21 DOOSAN HEAVY IND & CONSTR CO LTD

AI summary

Disclosed herein is a method of manufacturing an anode for in-situ sintering for a molten carbonate fuel cell, in which an anode green sheet is prepared using a slurry, and then a reinforcing layer is placed on the anode green sheet and then pressed, thereby improving the mechanical stability of a fuel cell stack and the long term stability of an anode, and an anode manufactured using the method.