Solid Oxide Fuel Cells (SOFC) are electrochemical energy conversion devices which allow fuel gases, e.g. hydrogen or natural gas, to be converted to electricity and heat at much high efficiencies than combustion-based energy conversion technologies. SOFC are particularly suited to employment in stationary energy conversion applications, e.g. micro-combined heat and power (μ-CHP) and base load, which are certain to play a large role in worldwide decentralisation of power distribution and supply over the coming decades. Use of high-temperature SOFC technology within these systems is also a vital requirement in order to utilise fuel gases which are readily available in different areas of the world. Unfortunately, the limiting factor to the long-term commercialisation of SOFC systems is the redox instability, coking intolerance and sulphur poisoning of the state-of-the-art Ni-based cermet composite anode material. This research explores the ‘powder to power' development of alternative SOFC anode catalyst systems by impregnation of an A-site deficient La0.20Sr0.25Ca0.45TiO3 (LSCT[sub](A-)) anode ‘backbone' microstructure with coatings of ceria-based oxide ion conductors and metallic electrocatalyst particles, in order to create a SOFC anode which exhibits high redox stability, tolerance to sulphur poisoning and low voltage degradation rates under operating conditions. A 75 weight percent (wt. %) solids loading LSCT[sub](A-) ink, exhibiting ideal properties for screen printing of thick-film SOFC anode layers, was screen printed with 325 and 230 mesh counts (per inch) screens onto electrolyte supports. Sintering of anode layers between 1250 °C and 1350 °C for 1 to 2 hours indicated that microstructures printed with the 230 mesh screen provided a higher porosity and improved grain connectivity than those printed with the 325 mesh screen. Sintering anode layers at 1350 °C for 2 hours provided an anode microstructure with an advantageous combination of lateral grain connectivity and porosity, giving rise to an ‘effective' electrical conductivity of 17.5 S cm−1 at 850 °C. Impregnation of this optimised LSCT[sub](A-) anode scaffold with 13-16 wt. % (of the anode mass) Ce0.80Gd0.20O1.90 (CGO) and either Ni (5 wt. %), Pd, Pt, Rh or Ru (2-3 wt. %) and integration into SOFC resulted in achievement of Area Specific Resistances (ASR) of as low as 0.39 Ω cm−2, using thick (160 μm) 6ScSZ electrolytes. Durability testing of SOFC with Ni/CGO, Ni/CeO2, Pt/CGO and Rh/CGO impregnated LSCT[sub](A-) anodes was subsequently carried out in industrial button cell test rigs at HEXIS AG, Winterthur, Switzerland. Both Ni/CGO and Pt/CGO cells showed unacceptable levels of degradation (14.9% and 13.4%, respectively) during a ~960 hour period of operation, including redox/thermo/thermoredox cycling treatments. Significantly, by exchanging the CGO component for the CeO2 component in the SOFC containing Ni, the degradation over the same time period was almost halved. Most importantly, galvanostatic operation of the SOFC with a Rh/CGO impregnated anode for >3000 hours (without cycling treatments) resulted in an average voltage degradation rate of < 1.9% kh−1 which, to the author's knowledge, has not previously been reported for an alternative, SrTiO3-based anode material. Finally, transfer of the Rh/CGO impregnated LSCT[sub](A-) anode to industrial short stack (5 cells) scale at HEXIS AG revealed that operation in relevant conditions, with low gas flow rates, resulted in accelerated degradation of the Rh/CGO anode. During a 1451 hour period of galvanostatic operation, with redox cycles and overload treatments, a voltage degradation of 19.2% was observed. Redox cycling was noted to briefly recover performance of the stack before rapidly degrading back to the pre-redox cycling performance, though redox cycling does not affect this anode detrimentally. Instead, a more severe, underlying degradation mechanism, most likely caused by instability and agglomeration of Rh nanoparticles under operating conditions, is responsible for this observed degradation. Furthermore, exposure of the SOFC to fuel utilisations of >100% (overloading) had little effect on the Rh/CGO co-impregnated LSCT[sub](A-) anodes, giving a direct advantage over the standard HEXIS SOFC. Finally, elevated ohmic resistances caused by imperfect contacting with the Ni-based current collector materials highlighted that a new method of current collection must be developed for use with these anode materials.

Solid Oxide Fuel Cells are fuel cells that operate at high temperatures usually in the range of 600oC to 1000oC and employ solid ceramics as the electrolyte. In Solid Oxide Fuel Cells oxygen ions (O2- ) are the ionic charge carriers. Solid Oxide Fuel Cells are known for their higher electrical efficiency of about 50-60% [1] compared to other types of fuel cells and are considered very suitable in stationary power generation applications. It is very important to study the effects of different parameters on the performance of Solid Oxide Fuel Cells and for this purpose the experimental or numerical simulation method can be adopted as the research method of choice. Numerical simulation involves constructing a mathematical model of the Solid Oxide Fuel Cell and use of specifically designed software programs that allows the user to manipulate the model to evaluate the system performance under various configurations and in real time. A model is only usable when it is validated with experimental results. Once it is validated, numerical simulation can give accurate, consistent and efficient results. Modeling allows testing and development of new materials, fuels, geometries, operating conditions without disrupting the existing system configuration. In addition, it is possible to measure internal variables which are experimentally difficult or impossible to measure and study the effects of different operating parameters on power generated, efficiency, current density, maximum temperatures reached, stresses caused by temperature gradients and effects of thermal expansion for electrolytes, electrodes and interconnects. iv Since Solid Oxide Fuel Cell simulation involves a large number of parameters and complicated equations, mostly Partial Differential Equations, the situation calls for a sophisticated simulation technique and hence a Finite Element Method (FEM) multiphysics approach will be employed. This can provide three-dimensional localized information inside the fuel cell. For this thesis, COMSOL Multiphysics® version 4.2a will be used for simulation purposes because it has a Batteries & Fuel Cells module, the ability to incorporate custom Partial Differential Equations and the ability to integrate with and utilize the capabilities of other tools like MATLAB ® , Pro/Engineer® , SolidWorks® . Fuel Cells can be modeled at the system or stack or cell or the electrode level. This thesis will study Solid Oxide Fuel Cell modeling at the cell level. Once the model can be validated against experimental data for the cell level, then modeling at higher levels can be accomplished in the future. Here the research focus is on Solid Oxide Fuel Cells that use hydrogen as the fuel. The study focuses on solid oxide fuel cells that use 3-layered, 4-layered and 6-layered electrolytes using pure YSZ or pure SCSZ or a combination of layers of YSZ and SCSZ. A major part of this research will be to compare SOFC performance of the different configurations of these electrolytes. The cathode and anode material used are (La0.6Sr0.4)0.95-0.99Co0.2Fe0.8O3 and Ni-YSZ respectively