BaCe0.8Fe0.1Ni0.1O3−δ-impregnated Ni–GDC by phase-inversion as an anode of solid oxide fuel cells with on-cell dry methane reforming

BaCe0.8Fe0.1Ni0.1O3−δ (BCFN) in a perovskite structure is impregnated consecutively by BCFN solution and BCFN suspension into a phase-inversion prepared NiO–Gd0.1Ce0.9O2−δ (GDC) scaffold as an anode for solid oxide fuel cells (SOFCs) with on-cell dry reforming of methane (DRM). The whole pore surface of the scaffold is covered by small BCFN particles formed by BCFN solution impregnation; the large pores near the scaffold surface are filled by BCFN aerogels with a high specific surface area produced by BCFN suspension impregnation, which act as a catalytic layer for on-cell DRM. After reduction, the anode consists of a Ni–GDC scaffold and BCFN particles with exsolved FeNi3 nanoparticles. This BCFN-impregnated Ni–GDC anode has higher electrical conductivity, electrochemical activity, and resistance to carbon deposition, with which the cell shows maximum power densities between 1.44 and 0.92 W·cm−2 when using H2 and between 1.09 and 0.50 W·cm−2 when using CO2–CH4 at temperatures ranging from 750 to 600 °C. A stable performance at 400 mA·cm−2 and 700 °C is achieved using 45% CO2–45% CH4–10% N2 for more than 400 h without carbon deposition, benefiting from the impregnated BCFN aerogel with a high specific surface area and water adsorbability.