Battelle Memorial Institute

Delphi Technologies, Inc.

Lawrence Andrew Chick

Vincent L Sprenkle

Kerry D Meinhardt

Jin Yong Kim

Karl Jacob Haltiner, Jr

Subhasish Mukerjee

Greg A Whyatt

Gregory J Exarhos

Larry R Pederson

Paul E George, Ii

Zhenguo Yang

Michael Roy Powell

Kenneth Scott Weil

Suresh Baskaran

Nathan L Canfield

Gary D Maupin

K Scott Weil

Christopher Andrew Coyle

Kurtis P Recknagle

Randal P Kurosky

Dean Paxton

John E Deibler

Jr Karl J Haltiner

Kenneth S Weil

Subhasish 157 Mukerjee

High power density solid oxide fuel cell steam reforming system and process for electrical generation

The present invention is a Solid Oxide Fuel Cell Reforming Power System that utilizes adiabatic reforming of reformate within this system. By utilizing adiabatic reforming of reformate within the system the system operates at a significantly higher efficiency than other Solid Oxide Reforming Power Systems that exist in the prior art. This is because energy is not lost while materials are cooled and reheated, instead the device operates at a higher temperature. This allows efficiencies higher than 65%.

Solid oxide fuel cell steam reforming power system

Lanthanum strontium cobalt iron oxides (La(1-x)SrxCoyFe1-yO3-f; (LSCF) have excellent power density (&#x3e;500 mW/cm2 at 750&#xb0; C.). When covered with a metallization layer, LSCF cathodes have demonstrated increased durability and stability. Other modifications, such as the thickening of the cathode, the preparation of the device by utilizing a firing temperature in a designated range, and the use of a pore former paste having designated characteristics and combinations of these features provide a device with enhanced capabilities.

Optimized cell configurations for stable LSCF-based solid oxide fuel cells

Methods for improving the sulfur-tolerance of nickel-based catalyst systems, as well as the improved catalyst systems, are disclosed. The methods can include adding praseodymium alone, or in combination with ruthenium and/or cerium, to a nickel-based catalyst system, thereby inhibiting sulfur poisoning of the catalyst system. Improved catalyst systems can have an added amount of praseodymium alone, or in combination with ruthenium and/or cerium, sufficient to inhibit poisoning of the system by sulfur.

Sulfur-tolerant catalyst systems

An interconnect system including: a separator plate to provide an anode gas flow space; a first metal interconnect disposed between the separator plate and an anode surface; a nickel oxide paste applied in a pattern over the surface of the anode and adjacent surface of the separator plate which when sintered results in a first conductive layer bonded to the anode and the first interconnect, and a second conductive layer bonded to the first interconnect and the separator plate; a second metal interconnect disposed between a cathode surface of the cell and the separator plate of an adjacent cell cassette; and a silver-containing paste applied over the surface of the cathode and the separator plate which when sintered results in a third conductive layer bonded to the cathode and the second interconnect, and a fourth conductive layer bonded to the second interconnect and the separator plate.

Solid bonded interconnect system in a lightweight solid oxide fuel cell stack

A modular fuel cell cassette for use in assembling a fuel cell stack comprising a metal separator plate and a metal cell-mounting plate joined at their edges to form a hollow cassette. A fuel cell subassembly is attached to the mounting plate and extends through an opening in the mounting plate. The plates include openings to form chimney manifolds for supply and exhaust of fuel gas to the anode and air to the cathode. A conductive interconnect element extends from the fuel cell subassembly to make contact with the next cassette in a stack. The anode openings in the mounting plate and separator plate are separated by spacer rings such that the cassette is incompressible. A fuel cell stack comprises a plurality of cassettes, the mounting plate of one cassette being attached to, and insulated from, the separator plate of the next-adjacent cassette by a dielectric seal surrounding the interconnect.

Modular fuel cell cassette for forming a solid-oxide fuel cell stack

A method of joining metal and metal, or metal and ceramic parts, wherein a first metal part is selected and then processed to form a bond coat that will effectively bond to a sealing material which in turn bonds to a second metal or ceramic part without degrading under the operating conditions of electrochemical devices. Preferred first metal parts include alumina forming alloys from the group consisting of ferritic stainless steels (such as Fecralloys), austinetic stainless steels, and superalloys, and chromia forming alloys formed of ferritic stainless steels. In the case of chromia forming ferritic stainless steels, this bond coat consists of a thin layer of alumina formed on the surface, with a diffusion layer between the first metal part and this thin layer. The bond coat provides a good bonding surface for a sealing layer of glass, braze or combinations thereof, while at the same time the diffusion layer provides a durable bond between the thin alumina layer and the first metal part. In the case of alumina forming alloys, the bond coat consists of cauliflower-like growths of an aluminum oxide nodules embedded in the surface of the alumina forming alloys.

Gas-tight metal/ceramic or metal/metal seals for applications in high temperature electrochemical devices and method of making

The present invention is a reactor for combustion synthesis of inorganic powders. The reactor includes a reaction vessel having a length and a first end and a second end. The reaction vessel further has a solution inlet and a carrier gas inlet. The reactor further has a heater for heating both the solution and the carrier gas. In a preferred embodiment, the reaction vessel is heated and the solution is in contact with the heated reaction vessel. It is further preferred that the reaction vessel be cylindrical and that the carrier gas is introduced tangentially into the reaction vessel so that the solution flows helically along the interior wall of the reaction vessel. As the solution evaporates and combustion produces inorganic material powder, the carrier gas entrains the powder and carries it out of the reactor.

Combustion synthesis continuous flow reactor

This invention is directed to the formation of homogeneous, aqueous precursor mixtures of at least one substantially soluble metal salt and a substantially soluble, combustible co-reactant compound, typically an amino acid. This produces, upon evaporation, a substantially homogeneous intermediate material having a total solids level which would support combustion. The homogeneous intermediate material essentially comprises highly dispersed or solvated metal constituents and the co-reactant compound. The intermediate material is quite flammable. A metal oxide powder results on ignition of the intermediate product which combusts same to produce the product powder.

Method of making metal oxide ceramic powders by using a combustible

A new chemical method of forming thin ceramic films has been developed. An aqueous solution of metal nitrates or other soluble metal salts and a low molecular weight amino acid is coated onto a substrate and pyrolyzed. The amino acid serves to prevent precipitation of individual solution components, forming a very viscous, glass-like material as excess water is evaporated. Using metal nitrates and glycine, the method has been demonstrated for zirconia with various levels of yttria stabilization, for lanthanum-strontium chromites, and for yttrium-barium-copper oxide superconductors on various substrates.

Preparation of thin ceramic films via an aqueous solution route

Growing community of inventors

West Richland, WA, United States of America

Lawrence Andrew Chick