固体酸化物セルの製造スケールアップ：実験室最適化から準工業的生産へ

Unofficial AI-generated summary based on the public title and abstract. Not an official translation.

🔬研究者:SOECのスケールアップ時における微細構造・電気化学特性の変化を定量化した実証データを提供する。

🏢実務担当者:水素製造装置の量産化・コスト低減を検討する製造業にとって、準工業的プロセス移行の実践的知見となる。

🏛政策担当者:水素・パワーtoX産業化支援策や製造サプライチェーン政策の設計に参考となる。

Solid oxide electrolysis cells (SOECs) are a promising technology for renewable hydrogen and power-to-X applications due to their high efficiency, reversible operation, and fuel flexibility. Yet, their high-temperature operation accelerates material degradation, limiting long-term durability, and reliable system integration. Although many advanced materials have been proposed, most developments remain at laboratory scale, hindering accurate predictions of industrial-scale performance. Here, we present the optimization and upscaling of a state-of-the-art SOEC architecture (Ni-YSZ/YSZ/GDC/LSCF), with special emphasis on how the transition from laboratory to pre-industrial manufacturing affects microstructure and electrochemical behavior. Building on the optimized laboratory-scale process, the next step was its transfer to a pre-industrial environment, a key stage to assess its real feasibility in production lines. This scale-up allowed us to examine how increases in size, slurry volume and process complexity influence material behaviour and the microstructure of each layer, as well as to redefine critical parameters to maintain suspension stability, layer uniformity and process reproducibility under larger-scale conditions. For the scale-up, the fabrication route was transferred to larger semiautomated equipment for milling, tape casting and sintering. The tape casting step was adapted to a pre-industrial roll-to-roll system with particular attention to the increase in slurry volume and its effect on rheology, particle dispersion and final layer structure. Optimized casting conditions were redefined to obtain homogeneous, and defect-free tapes up to14 m in length. The process was also adjusted to enable multilayer casting, ensuring stable deposition of consecutive layers with controlled interfaces. In parallel, the sintering protocol was optimized to co-sinter multiple large-area cells while preserving flatness and good interlayer adhesion. The resulting cells were validated through microstructural analysis and electrochemical testing, confirming that the pre-industrial route successfully maintains the quality and performance of the lab-scale process, demonstrating the feasibility of its transfer toward industrial manufacturing. Additionally, this approach has enabled a significant reduction in production costs and lead times, as well as improved manufacturing reproducibility.

• Zenodo https://zenodo.org/records/23009011first seen 2026-10-01 04:13:44 · last seen 2026-10-02 04:13:58