Metal-Supported Anode with Segmented Pores for Internal Reforming
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional solid oxide electrochemical devices operating with non-hydrogen fuels require external reformers, which increase space and cost, and internal reforming catalysts add internal resistance, reducing power output and extending start-up and cool-down times.
Innovation Solution
The implementation of a metal-supported anode layer with a reformer catalyst having a diameter greater than the pore diameter, deposited on the surface of channels within the anode structure, allowing for internal reforming of fuels like methane and ethanol without compromising power density or increasing ohmic resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If internal reforming catalyst is used to reform non-hydrogen fuels, then external reformer space and cost are reduced, but internal resistance increases and power output decreases
Solution Approach 1:
The anode is segmented into distinct functional zones: a reforming zone with catalyst particles in larger pores for fuel reforming, and a power generation zone with catalyst in smaller pores for electrochemical reactions. This spatial segmentation allows each zone to perform its specific function optimally without the reforming catalyst compromising overall power output.
Solution Approach 2:
Different pore sizes are used in different regions of the anode to create local quality variations. Larger pores (5-20 μm) in the reforming zone accommodate reforming catalyst particles (1-5 μm) for efficient fuel conversion, while smaller pores (0.1-1 μm) in the power generation zone optimize electrochemical performance. This local differentiation resolves the contradiction between reforming efficiency and power output.
2Ease of manufacture
If reforming catalyst is deposited in pores, then internal reforming is achieved, but catalyst blocks pores and increases ohmic resistance
Solution Approach 1:
The anode pore structure is segmented into two distinct size categories: larger pores (5-20 μm) that accommodate reforming catalyst particles without blocking, and smaller pores (0.1-1 μm) that maintain electrical conductivity for power generation. This segmentation allows internal reforming capability while preventing ohmic resistance increase.
Solution Approach 2:
The anode utilizes a hierarchical porous structure with bimodal pore size distribution. The larger pores provide channels for catalyst placement and reforming reactions without impeding electron transport, while the smaller pores maintain continuous conductive pathways. This porous material design enables internal reforming while minimizing energy losses.
3Productivity
If high operating temperature is used for solid oxide electrochemical devices, then fuel conversion efficiency is improved, but start-up and cool-down time extend
Solution Approach 1:
The invention optimizes the pore size parameters and catalyst particle size parameters to enhance heat transfer efficiency. The hierarchical pore structure with larger pores facilitates faster heat distribution throughout the anode, enabling the device to reach optimal operating temperature more quickly while maintaining high fuel conversion efficiency.
Solution Approach 2:
The anode employs a composite structure combining metal support material with bifunctional catalyst particles of different sizes. This composite material design improves thermal conductivity and heat distribution, reducing start-up and cool-down times while preserving the high-temperature fuel conversion efficiency required for optimal performance.
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 solution reduces internal resistance, improves heating and cooling times, and maintains power density by enabling efficient conversion of hydrocarbons to hydrogen and carbon monoxide within the device, minimizing the need for external reformers and enhancing start-up and cool-down performance.
Implementation Method 1
a first reformer catalyst deposited onto surfaces of the metal support structure defining the channels, the first reformer catalyst having a diameter greater than the pore diameter. The anode layer can further comprise a second reformer catalyst, with the first reformer catalyst reforming a first fuel and the second reformer catalyst reforming a second fuel.
Data Source
AI summary
An anode layer for a solid oxide electrochemical device comprises a metal support structure having an electrolyte-facing surface and a gas distribution-facing surface, the metal support structure defining pores having a pore diameter, anode catalyst supported within the metal support structure, channels formed within the gas distribution-facing surface of the metal support structure, and a first reformer catalyst deposited onto surfaces of the metal support structure defining the channels, the first reformer catalyst having a diameter greater than the pore diameter. The anode layer can further comprise a second reformer catalyst, with the first reformer catalyst reforming a first fuel and the second reformer catalyst reforming a second fuel.