Solid Oxide Electrolysis Cells Fabrication: From Single Cells to Batch Production

Energy transition towards a net-zero emission scenario requires, primarily, a significant increase on the renewable energy production capabilities. However, the inherent intermittency of most common renewable sources, added to the limitations of full electrification in some important hard-to-abate sectors (heavy-duty transport, aviation, steel industry...), implies also the need of developing reliable solutions for energy conversion and storage. Here, hydrogen is gaining more and more popularity in the recent years as an effective solution as energy carrier, mostly for the decarbonization of the key industries and transport. Among the different technologies under development for power-to-hydrogen conversion, solid oxide electrolysis (SOE) outstands due to its high conversion efficiency, fuel flexibility (e.g. CO 2 electrolysis) and possibility of working in reversible mode (the same device both as electrolyser and fuel cell). Currently behind competing low temperature electrolysis technologies (AEL, PEMEL) in terms of technology readiness, main challenges of SOE today relate to long-term degradation, heat management and design and reliable fabrication of large stacks and systems. Although many projects are lately flourishing in this line, the number of players able to demonstrate an upscaled fabrication of SOE stacks and systems is still limited. The work presented here represents the first step carried out at CENER for the future demonstration of a pilot fabrication line of SOE stacks, from the optimization of functional materials and inks to the fabrication of single cells and building of 2-10 kW stacks. In this study, a fabrication route for SOE planar cells (5x5 cm 2 ) is proposed, including the optimization of every single step of the process: raw material pre-treatment, ink/slurry development, functional printing and sintering. Particular emphasis is placed on ensuring a reliable upscaling for batch production of cells and thus materials are processed in large quantities (~1 L/batch). In terms of functional materials, standard electrode and electrolytes are chosen in a first approach, viz. Ni-YSZ as hydrogen electrode, YSZ as electrolyte and LSM-YSZ as air electrode. For film deposition, tape casting and screen printing techniques are combined. The electrochemical characterization of the fabricated cells will be presented and compared with commercial ones, including degradation analysis.