Redox Tolerant Cathode for Solid Oxide Electrolysis Stacks

In Phase II of the SBIR project, a modified cathode composition and an alternative current collector composition were evaluated. The objectives proposed were to demonstrate redox tolerance and rapid thermal cycle capability. Both objectives were met well ahead of schedule. Additional tasks demonstrated reversibility (switching between electrolysis and fuel cell operation) and evaluate coking resistance of the newly developed cathode and current collector compositions. Performance degradation is a critical issue for solid oxide stacks operating as fuel cells (SOFC) or electrolysis cells (SOEC). A variety of SOFC degradation mechanisms have been investigated by the research community over the last three decades but limited work has been done to address SOEC degradation. However, while it is generally accepted that many of the mechanisms are common to both modes of operation, some mechanisms manifest only in SOEC mode. Prior to MOXIE development, OxEon successfully addressed two sources of degradation for SOECs: coarsening of Ni based fuel electrode and oxygen electrode delamination during operation. Other degradation mechanisms will be evaluated in Phase II E. They are related to electrode poisoning, electrode thermochemical instability, and non-catalytic secondary phases. Additionally, it is likely that the dominant degradation mechanism may be different in different modes of operation, e.g., dry CO2 electrolysis, steam electrolysis, and fuel cell modes. Phase II E will systematically address these issues and and deliver an SOEC stack that demonstrates performance stability.

The intended target application is Mars ISRU. Specifically, the electrolysis stacks will generate oxygen and fuel on Mars using in-situ resource such as carbon dioxide from Martian atmosphere and subsurface water. The same device can be used to produce liquid hydrogen and liquid oxygen for lunar applications.

The stacks will be used to produce hydrogen and oxygen by steam electrolysis. The intended application for the produced hydrogen is for transportation. Co-electrolysis of CO2 and H2O to produce synthesis gas which can be either converted to synthetic methane or liquid hydrocarbon fuels. The primary target application is the storage of intermittent renewable energy.

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