Layered anode system for electrochemical applications and process of manufacturing the same

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This invention discloses a layered, porous anode system for electrochemical devices, particularly high-temperature solid oxide fuel cells (SOFCs). The system consists of at least two layers: a primary support layer mainly composed of zirconium (such as yttria-stabilized zirconia), and a secondary functional anode layer mainly composed of cerium (such as gadolinium-doped ceria). This structure is optimized for use at operating temperatures between 400°C and 750°C, and provides high porosity (≥30%), facilitating gas flow and enhancing performance. The patent also covers methods for manufacturing this multilayer anode system.

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• Anodes for high-temperature solid oxide fuel cells (SOFCs), for stationary or mobile power generation.
• Anodes for oxygen transport membranes used in gas separation and purification.
• Electrodes in metal-metal oxide batteries.
• Electrochemical devices requiring robust, high-performance anodes operating at moderate to high temperatures (400–750°C).

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• Enables SOFC operation at lower temperatures (below 650°C), thereby increasing system lifespan and stability.
• Uses inexpensive zirconium-based materials for the support, substantially reducing rare earth oxide consumption by over 97% compared to fully ceria-based anodes, thus reducing costs.
• High porosity improves gas diffusion and reaction efficiency within the electrode, promoting better fuel utilization and electrical performance.
• The double-layer structure allows robust mechanical support, minimizing the risk of degradation during operation.
• Simplifies manufacturing by making an explicit diffusion barrier layer unnecessary; the functional interface forms naturally during processing.

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Patent Abstract

A porous anode layer system has at least two layers in which primary layer contains zirconium as main component and secondary layer comprises cerium as main component. The porous anode layer system has total porosity of 30 volume% or more. Independent claims are included for the following: (1) usage of porous anode layer system as anode for high-temperature fuel cell which is operating at 400-750[deg] C, preferably less than 650[deg] C; and (2) manufacture of porous anode layer system.