Application of mist pyrolysis method to preparation of Ni/ZrO2 anode catalyst for SOFC type reactor

The ultrasonic mist pyrolysis method (mist method), a novel technique for the production of fine powders, is applied to the preparation of cermet anodes for solid oxide fuel cell (SOFC) reactors. This method is very useful for the fixation of micron-scale metal-oxide cermet powders on the YSZ substrate. The powders are spherical, well dispersed and homogeneous. The oxidation of methane was studied in a SOFC reactor with Ni/ZrO2 anodes. The Ni/ZrO2 cermet prepared by the mist method was selective for the oxidative coupling of methane (OCM), while the Ni/ZrO2 cermet prepared by the ordinary paste method was active for CO and CO2 formation. Although the supported amount of the mist anode was 100 times less than the supported amount of the paste one, both anodes showed similar total yields. The variations in activity and selectivity may be due to the different morphologies resulting from the two preparation methods.