Nickel Coarsening and Mass Transfer Performance Prediction in Direct Internal Reforming Solid Oxide Fuel Cells

Ni coarsening is a primary degradation mechanism in Ni-based anodes, significantly contributing to performance decline and diminished lifespan of methane steam reforming solid oxide fuel cells (SOFCs) during long-term operation. In this study, a novel algorithm is introduced to reconstruct two-dimensional Ni-YSZ anode microstructures, complemented by the development of a multi-physics model that integrates phase-field modeling (PFM) with the Lattice Boltzmann Method (LBM). This coupled PFM-LBM framework is employed to investigate the effects of Ni agglomeration on microstructural evolution and methane-steam mass transport under diverse conditions. The results demonstrate that the initial Ni particle diameter exerts a significant influence on Ni agglomeration dynamics. Furthermore, the mass transport analysis reveals that the necking structures formed during Ni coarsening pose a substantial impediment to mass transfer efficiency. Finally, optimized structural parameters for Ni-YSZ are proposed to enhance anode performance in Ni-based electrodes.