TWO-LAYER ANODE FOR MOLTEN CARBONATE FUEL CELLS

1 . An anode, comprising:

a first layer comprising a first active material, the first active material comprising a NiAl alloy or a mixture of a NiAl alloy and a NiCr alloy, and

a second layer comprising a second active material and a ceramic material, the second active material comprising a NiAl alloy, a NiCr alloy, or a mixture thereof.

2 . The anode of claim 1 , wherein the first layer and the second layer further comprise a binder.

3 . The anode of claim 1 , wherein the first layer and the second layer have a thickness in a range of 50 μm to 125 μm.

4 . The anode of claim 1 , wherein the first active material and the second active material have a particle size in a range of 4 μm to 20 μm.

5 . The anode of claim 1 , wherein the first active material comprises the mixture of the NiAl alloy and the NiCr alloy, with the NiCr alloy present in an amount in a range of 10 wt. % to 50 wt. %.

6 . The anode of claim 1 , wherein the second active material comprises a mixture of the NiAl alloy in an amount in a range of 10 wt. % to 90 wt. % and the NiCr alloy in an amount in a range of 10 wt. % to 90 wt. %.

7 . The anode of claim 1 , wherein the ceramic material comprises of LiAlO 2 , ZrO 2 , CeO 2 , Li 2 ZrO 3 , Y 2 O 3 , Al 2 O 3 , yttria-stabilized zirconia, or a mixture thereof.

8 . The anode of claim 7 , wherein the ceramic material comprises LiAlO 2 .

9 . The anode of claim 1 , wherein the ceramic material has an average particle size in a range of 0.001 μm to 0.5 μm.

10 . The anode of claim 1 , wherein the ceramic material is present in an amount in a range of 10 wt. % to 60 wt. % in the second layer.

11 . The anode of claim 1 , wherein the anode further comprises a porous anode support.

12 . A method for making a two-layer anode, comprising:

forming a first layer from a first slurry;

forming a second layer from a second slurry;

drying the first layer and the second layer; and

laminating the first layer, the second layer, and a nickel-based porous anode support to form the two-layer anode.

13 . The method of claim 12 , wherein the step of forming the first layer and/or the step of forming the second layer is performed using at least one of a tape-casting process, a spray coating process, or a screen printing process.

14 . The method of claim 13 , wherein the step of forming the first layer is performed using a tape-casting process and the step of forming the second layer is performed using a tape-casting process.

15 . The method of claim 12 , wherein the second layer is tape-cast directly on the first layer, without an intervening drying step, and wherein the first layer is tape-cast directly on an electrolyte matrix layer.

16 . The method of claim 12 , further comprising:

preparing the first slurry by mixing a binder solution and an active material, wherein the active material comprises a NiAl alloy or a mixture of a NiAl alloy and a NiCr alloy.

17 . The method of claim 12 , further comprising:

preparing the second slurry by mixing a binder solution, an active material and a ceramic material, wherein the active material comprises a NiAl alloy, a NiCr alloy, or a mixture thereof.

18 . The method of claim 12 , further comprising:

forming a binder solution for inclusion in the first slurry or the second slurry, wherein the step of forming the binder solution includes mixing a binder, a dispersant, a plasticizer and a solvent.

19 . The method of claim 12 , wherein the step of drying the first layer and the second layer is conducted at a temperature in a range of 25° C. to 30° C. for a time in a range of 30 min to 50 min.

20 . A fuel cell, comprising:

an anode according to claim 1 , wherein the first layer is disposed adjacent to an anode current collector and the second layer is disposed adjacent to an electrolyte matrix.