Design of next-generation ceramic fuel cells and real-time characterization with synchrotron X-ray diffraction computed tomography

Micromonolithic Electrochemical Cells for Sustainable Syngas Production from H2O and CO2

The direct conversion of CO2, preferably from direct air capture (DAC), and H2O from seawater to syngas by renewable electricity, offers an alternative route toward a sustainable future for the chemical industry. To achieve this ambitious goal, an efficient electrochemical conversion route is preferred. However, high-performance and cost-effective devices for achieving such sustainable production are lacking. Here, we report an innovative micromonolithic solid oxide electrolysis cell (SOEC) device with a productivity of -2.4 A/cm2 at 1.4 V and an operational stability of ∼ -1.0 A/cm2 (-11.7 A/cm3, 4387 N m3 syngas/h/m3) for 110 h; this device has an almost 1 order of magnitude greater cost-effectiveness and has substantial environmental benefits compared to conventional tubular and planar designs. The conceptual process design of prospective sustainable electrified syngas production has the potential to achieve 0.1 $/Nm3 syngas and -0.92 kgCO2/kgsyngas. Moreover, microstructural sensitivity, three-stage degradation mechanism, and mechanical features of the cell are studied to provide deep insights.

From biomass to power: High-performance reactor design for coking-resistant operation

Biomass gasification coupled with solid oxide fuel cell (SOFC) technology utilizes the gas generated from biomass gasification directly as fuel for SOFC, thereby realizing power generation from solid waste. This technology combines the carbon-neutral feature of biomass with the high efficiency and low emissions of SOFC, making it a promising route for clean energy generation. However, biomass gasification syngas possesses a complex composition, including a high concentration of inert gases, which imposes higher requirements on SOFC. This study developed a multi-channel, hierarchical structural design based on the commercial NiO-yttria-stabilized zirconia (YSZ) material system, realizing high-performance power generation using biomass gasification syngas. The results showed that the combination of a unique structural design and an enhanced interface electrochemical reaction effectively mitigates the influence from inert composition dilution. When operating in gasification syngas with nearly 60 % inert components, the power density can reach 2.07 W·cm-2 (750 °C). In addition, due to the spatial separation of the inert support region and the electrochemically active region, the effect of controlling the position of carbon deposits was achieved, demonstrating 100 h stable operation with dry biomass gasification syngas. Hence, the combination of micro-tubular SOFC with distinctive structural regulation and biomass gasification exhibits promising prospects for further development.

Visualization of CO2 electrolysis using optical coherence tomography

Electrolysers offer an appealing technology for conversion of CO2 into high-value chemicals. However, there are few tools available to track the reactions that occur within electrolysers. Here we report an electrolysis optical coherence tomography platform to visualize the chemical reactions occurring in a CO2 electrolyser. This platform was designed to capture three-dimensional images and videos at high spatial and temporal resolutions. We recorded 12 h of footage of an electrolyser containing a porous electrode separated by a membrane, converting a continuous feed of liquid KHCO3 to reduce CO2 into CO at applied current densities of 50-800 mA cm-2. This platform visualized reactants, intermediates and products, and captured the strikingly dynamic movement of the cathode and membrane components during electrolysis. It also linked CO production to regions of the electrolyser in which CO2 was in direct contact with both membrane and catalyst layers. These results highlight how this platform can be used to track reactions in continuous flow electrochemical reactors.

In Situ and Operando X-ray Scattering Methods in Electrochemistry and Electrocatalysis

Electrochemical and electrocatalytic processes are of key importance for the transition to a sustainable energy supply as well as for a wide variety of other technologically relevant fields. Further development of these processes requires in-depth understanding of the atomic, nano, and micro scale structure of the materials and interfaces in electrochemical devices under reaction conditions. We here provide a comprehensive review of in situ and operando studies by X-ray scattering methods, which are powerful and highly versatile tools to provide such understanding. We discuss the application of X-ray scattering to a wide variety of electrochemical systems, ranging from metal and oxide single crystals to nanoparticles and even full devices. We show how structural data on bulk phases, electrode-electrolyte interfaces, and nanoscale morphology can be obtained and describe recent developments that provide highly local information and insight into the composition and electronic structure. These X-ray scattering studies yield insights into the structure in the double layer potential range as well as into the structural evolution during electrocatalytic processes and phase formation reactions, such as nucleation and growth during electrodeposition and dissolution, the formation of passive films, corrosion processes, and the electrochemical intercalation into battery materials.

Direct 4D printing of ceramics driven by hydrogel dehydration

4D printing technology combines 3D printing and stimulus-responsive materials, enabling construction of complex 3D objects efficiently. However, unlike smart soft materials, 4D printing of ceramics is a great challenge due to the extremely weak deformability of ceramics. Here, we report a feasible and efficient manufacturing and design approach to realize direct 4D printing of ceramics. Photocurable ceramic elastomer slurry and hydrogel precursor are developed for the fabrication of hydrogel-ceramic laminates via multimaterial digital light processing 3D printing. Flat patterned laminates evolve into complex 3D structures driven by hydrogel dehydration, and then turn into pure ceramics after sintering. Considering the dehydration-induced deformation and sintering-induced shape retraction, we develop a theoretical model to calculate the curvatures of bent laminate and sintered ceramic part. Then, we build a design flow for direct 4D printing of various complex ceramic objects. This approach opens a new avenue for the development of ceramic 4D printing technology.

Enhanced Antioxidant Effects of Naringenin Nanoparticles Synthesized using the High-Energy Ball Milling Method

Naringenin, one of the flavonoid components, is majorly found in and obtained from grapefruits and oranges. Naringenin also acts as a potent antioxidant, which possesses hypolipidemic as well as anti-inflammatory potential. Naringenin reduces the expressions of several inflammatory mediators, viz., NF-κB, cycloxygenase-2, and other cytokine mediators. In spite of having various biological effects, the clinical application of naringenin is restricted due to its very poor aqueous solubility. In the present study, the high-energy ball milling method was employed for the preparation of naringenin nanoparticles without using any chemical with an aim to enhance the anti-oxidant potential of naringenin. The milled naringenin nanoparticles were characterized for their physicochemical properties using scanning electron microscopy (SEM) and X-ray diffraction. Additionally, the effects of milling time and temperature were further assessed on the solubility of crude and milled naringenin samples. The antioxidant potential of milled naringenin was evaluated with various assays such as DHE, DCFDA, and cleaved caspase-3 using SH-SY5Y human neuroblastoma cells. The nanoparticle size of naringenin after milling was confirmed using SEM analysis. Crystalline peaks for milled and crude samples of naringenin also established that both the naringenin forms were in the crystalline form. The solubility of naringenin was enhanced depending on the milling time and temperature. Moreover, crude and milled naringenin were found to be cytocompatible up to doses of 120 μM each for the duration of 24 and 48 h. It was also observed that milled naringenin at the doses of 1, 2, and 5 μM significantly reduced the levels of reactive oxygen species (ROS) generated by H₂O₂ and exhibited superior ROS scavenging effects as compared to those of crude or un-milled forms of naringenin. Furthermore, milled naringenin at the doses of 1 and 2 μM inhibited H₂O₂-induced cell death, as shown by immunofluorescence staining of cleaved caspase-3 and Annexin-V PI flow cytometry analysis. Conclusively, it could be suggested that the size reduction of naringenin using high-energy ball milling techniques substantially enhanced the antioxidant potential as compared to naïve or crude naringenin, which may be attributed to its enhanced solubility due to reduced size.

Initial Assessment of a Fuel Cell—Gas Turbine Hybrid Propulsion Concept

A fuel cell—gas turbine hybrid propulsion concept is introduced and initially assessed. The concept uses the water mass flow produced by a hydrogen fuel cell in order to improve the efficiency and power output of the gas turbine engine through burner steam injection. Therefore, the fuel cell product water is conditioned through a process of condensation, pressurization and re-vaporization. The vaporization uses the waste heat of the gas turbine exhaust. The functional principles of the system concept are introduced and discussed, and appropriate methodology for an initial concept evaluation is formulated. Essential technology fields are surveyed in brief. The impact of burner steam injection on gas turbine efficiency and sizing is parametrically modelled. Simplified parametric models of the fuel cell system and key components of the water treatment process are presented. Fuel cell stack efficiency and specific power levels are methodically derived from latest experimental studies at the laboratory scale. The overall concept is assessed for a liquid hydrogen fueled short-/medium range aircraft application. Block fuel savings of up to 7.1% are found for an optimum design case based on solid oxide fuel cell technology. The optimum design features a gas turbine water-to-air ratio of 6.1% in cruise and 62% reduced high-level NOx emissions.

Powder diffraction computed tomography: a combined synchrotron and neutron study

Diffraction and imaging using x-rays and neutrons are widely utilized in different fields of engineering, biology, chemistry and/or materials science. The additional information gained from the diffraction signal by x-ray diffraction and computed tomography (XRD-CT) can give this method a distinct advantage in materials science applications compared to classical tomography. Its active development over the last decade revealed structural details in a non-destructive way with unprecedented sensitivity. In the current contribution an attempt to adopt the well-established XRD-CT technique for neutron diffraction computed tomography (ND-CT) is reported. A specially designed 'phantom', an object displaying adaptable contrast sufficient for both XRD-CT and ND-CT, was used for method validation. The feasibility of ND-CT is demonstrated, and it is also shown that the ND-CT technique is capable to provide a non-destructive view into the interior of the 'phantom' delivering structural information consistent with a reference XRD-CT experiment.

DLSR: a solution to the parallax artefact in X-ray diffraction computed tomography data

A new tomographic reconstruction algorithm is presented, termed direct least-squares reconstruction (DLSR), which solves the well known parallax problem in X-ray-scattering-based experiments. The parallax artefact arises from relatively large samples where X-rays, scattered from a scattering angle 2θ, arrive at multiple detector elements. This phenomenon leads to loss of physico-chemical information associated with diffraction peak shape and position (i.e. altering the calculated crystallite size and lattice parameter values, respectively) and is currently the major barrier to investigating samples and devices at the centimetre level (scale-up problem). The accuracy of the DLSR algorithm has been tested against simulated and experimental X-ray diffraction computed tomography data using the TOPAS software.

The Detection of Monoclinic Zirconia and Non-Uniform 3D Crystallographic Strain in a Re-Oxidized Ni-YSZ Solid Oxide Fuel Cell Anode

The solid oxide fuel cell (SOFC) anode is often composed of nickel (Ni) and yttria-stabilized zirconia (YSZ). The yttria is added in small quantities (e.g., 8 mol %) to maintain the crystallographic structure throughout the operating temperatures (e.g., room-temperature to >800 °C). The YSZ skeleton provides a constraining structural support that inhibits degradation mechanisms such as Ni agglomeration and thermal expansion miss-match between the anode and electrolyte layers. Within this structure, the Ni is deposited in the oxide form and then reduced during start-up; however, exposure to oxygen (e.g., during gasket failure) readily re-oxidizes the Ni back to NiO, impeding electrochemical performance and introducing complex structural stresses. In this work, we correlate lab-based X-ray computed tomography using zone plate focusing optics, with X-ray synchrotron diffraction computed tomography to explore the crystal structure of a partially re-oxidized Ni/NiO-YSZ electrode. These state-of-the-art techniques expose several novel findings: non-isotropic YSZ lattice distributions; the presence of monoclinic zirconia around the oxidation boundary; and metallic strain complications in the presence of variable yttria content. This work provides evidence that the reduction–oxidation processes may destabilize the YSZ structure, producing monoclinic zirconia and microscopic YSZ strain, which has implications upon the electrode’s mechanical integrity and thus lifetime of the SOFC.

Spatial quantification of dynamic inter and intra particle crystallographic heterogeneities within lithium ion electrodes

The performance of lithium ion electrodes is hindered by unfavorable chemical heterogeneities that pre-exist or develop during operation. Time-resolved spatial descriptions are needed to understand the link between such heterogeneities and a cell's performance. Here, operando high-resolution X-ray diffraction-computed tomography is used to spatially and temporally quantify crystallographic heterogeneities within and between particles throughout both fresh and degraded Li_xMn₂O₄ electrodes. This imaging technique facilitates identification of stoichiometric differences between particles and stoichiometric gradients and phase heterogeneities within particles. Through radial quantification of phase fractions, the response of distinct particles to lithiation is found to vary; most particles contain localized regions that transition to rock salt LiMnO₂ within the first cycle. Other particles contain monoclinic Li₂MnO₃ near the surface and almost pure spinel Li_xMn₂O₄ near the core. Following 150 cycles, concentrations of LiMnO₂ and Li₂MnO₃ significantly increase and widely vary between particles.

Strategy for Controlling the Properties of Bioactive Poly-Ether-Ether-Ketone/Hydroxyapatite Composites for Bone Tissue Engineering Scaffolds

A strategy for the preparation of bioactive poly-ether-ether-ketone/hydroxyapatite (PEEK/HA) composites was proposed in this study with the aim of controlling the biological and mechanical properties of different parts of the composites. The strategy integrated solvent-based extrusion freeforming 3D printing technology in order to print high-resolution HA scaffolds and compression molding processes for the production of bioactive PEEK/HA composites. To this end, an optimized model, established using response surface methodology, was employed to optimize the extrusion process parameters on the basis of accurate characterization of the extrusion pressure, and the effects of the filament/pore sizes on the PEEK infiltration depth into the HA scaffold were investigated. The results of scanning electron microscopy and computed tomography analyses revealed that the PEEK/HA composites exhibited a uniform microstructure and a good interface between the HA filaments and the PEEK matrix following the optimization of the process parameters. The HA scaffolds were fully infiltrated by PEEK in both vertical and lateral directions with an infiltration depth of 3 mm while maintaining the HA network structure and uniformity. The biological and mechanical performance test results validated that the PEEK/HA composites possessed excellent biocompatibility as well as yields and compressive strengths within the range of human cortical bone suitable for load-bearing applications.