A robust direct-propane solid oxide fuel cell with hierarchically oriented full ceramic anode consisting with in-situ exsolved metallic nano-catalysts

Perovskite oxide Sr2Fe1.3Mo0.5Ni0.2O6-σ (SFMNi) impregnated on the scaffold of hierarchically oriented yttria-stabilized zirconia (YSZ) with open, straight pores (SFMNi@YSZ), that could transformed into in-situ exsolved Ni–Fe alloy nanoparticles structured SFMNi@YSZ (NiFe@SFMNi@YSZ) electrode, have been prepared and utilized for robust direct propane-fueled solid oxide fuel cell (SOFC). The hierarchically oriented open, straight pores can not only significantly facilitate the introduction of uniformly distributed SFMNi nano-catalyst network via the ion-impregnation method, but also greatly enhance the gas diffusion process in the porous electrode, thus greatly minimizing even eliminating the concentration resistance. The impregnated SFMNi nano-catalysts, especially the in-situ exsolved Ni–Fe alloy nano-catalysts, could effectively activate the fuel gas oxidation reaction in the anode, thereby drastically decreasing the activation resistance and enhancing the cell performance. The full ceramic electrode can efficiently avoid electrode aggregation and carbon coking, leading to excellent stability towards propane oxidation. Our findings indicate that NiFe@SFMNi@YSZ full ceramic electrode with hierarchically oriented open, straight pores offers a great promise for direct hydrocarbon SOFC.