Electrode-supported tubular solid-oxide electrochemical cell

Abstract

Electrode-supported tubular solid-oxide electrochemical cells suitable for use in electrochemical chemical synthesis and processes for manufacturing such are provided.

1 - 16 . (canceled) 
     
     
         17 . A tubular solid-oxide electrochemical cell made by a process comprising the steps of:
 extruding an electrode dough in a tubular shape to form a first electrode, the electrode dough comprising a solid-oxide electrolyte substance, a first electrochemically active substance, a carbon-based pore forming substance, a binder and a solvent;   sintering the extruded first electrode to cause the carbon-based pore forming substance to burn off and form pores in the first electrode;   forming an electrolyte onto at least part of a surface of the sintered first electrode, the electrolyte comprising a thin-layer of the solid-oxide electrolyte substance; and   forming a second electrode onto at least part of a surface of the electrolyte, the second electrode comprising the solid-oxide electrolyte substance and a second electrochemically active substance.   
     
     
         18 . The tubular solid-oxide electrochemical cell of  claim 17 , wherein the first electrochemically active substance and the second electrochemically active substance are the same. 
     
     
         19 . The tubular solid-oxide electrochemical cell of  claim 17 , wherein forming the electrolyte comprises:
 coating an electrolyte slurry onto at least part of the surface of the sintered first electrode, the electrode slurry comprising the solid-oxide electrolyte substance and a second solvent; and   drying and sintering the coated electrolyte.   
     
     
         20 . The tubular solid-oxide electrochemical cell of  claim 17 , wherein forming the second electrode comprises:
 coating an electrode slurry onto at least part of the surface of the electrolyte, the electrolyte slurry comprising the solid-oxide electrolyte substance, the second electrochemically active metallic substance, a second carbon-based pore forming substance, and a third solvent; and   drying and sintering the coated second electrode to cause the second carbon-based pore forming substance to hum off and form pores in the second electrode.   
     
     
         21 . A process for manufacturing a tubular solid-oxide electrochemical cell, the process comprising:
 forming an electrode dough comprising a solid-oxide electrolyte substance, a first electrochemically active substance, a first carbon-based pore forming substance, a first binder and a first solvent;   extruding the electrode dough in a tubular shape to form a first electrode; sintering the extruded first electrode;   forming an electrolyte slurry comprising the solid-oxide electrolyte substance and a second solvent;   coating the electrolyte slurry onto at least part of a surface of the sintered first electrode: sintering the electrolyte coating;   forming an electrode slurry comprising the solid-oxide electrolyte substance, a second electrochemically active substance, a second carbon-based pore forming substance, and a third solvent;   coating the electrode slurry onto at least part of a surface of the sintered electrolyte; and sintering the electrode coating.   
     
     
         22 . The process of  claim 21 , wherein forming the electrode dough comprises:
 mixing and milling the solid-oxide electrolyte substance, the first electrochemically active substance, and the first carbon-based pore forming substance to form a milled mixture of ingredients;   drying the milled mixture of ingredients; and   adding the first hinder and the first solvent into the dried milled mixture of ingredients.   
     
     
         23 . The process of  claim 21 , wherein the electrode dough further comprises at least one component selected from the group consisting of: a dispersant, a polymer, a cross-linker, an initiator, a catalyst, a plasticizer, a viscosity modifier, a flocculent, and a lubricant. 
     
     
         24 . The process of  claim 21 , wherein the electrode dough comprises about 30% to about 70% by volume of solid ingredients. 
     
     
         25 . The process of  claim 21 , wherein sintering the extruded first electrode comprises: gradually heating to a set temperature between about 800° C. to about 1600° C.; and holding at the set temperature for up to about 12 hours. 
     
     
         26 . The process of  claim 21 , wherein the electrolyte slurry further comprises at least one component selected from the group consisting of: a second binder, a dispersant, a polymer, a cross-linker, an initiator, a catalyst, and a plasticizer. 
     
     
         27 . The process of  claim 21 , wherein the electrolyte slurry comprises about 10% to about 30% by volume of solid ingredients. 
     
     
         28 . The process of  claim 21 , wherein the electrode slurry further comprises at least one component selected from the group consisting of: a dispersant, a polymer, a cross-linker, an initiator, a catalyst, and a plasticizer. 
     
     
         29 . The process of  claim 21 , wherein the electrode slurry comprises about 10% to about 30% by volume of solid ingredients.