A design of and the process for forming a rigidly bonded metal supported electro-chemical device stack is provided. The electro-chemical device stack can be a solid oxide fuel cell or solid oxide electrolysis stack. The stack comprises multiple planar cells connected in serial by planar metal interconnects. The cells have metal support layers on both anode and cathode sides. The interconnect has gas channels embedded. Thin ceramic electro-chemical active electrodes and electrolyte are sandwiched between the metal support layers. The cells and interconnects are rigidly bonded to form a rigid body stack. The process comprises the steps of a). forming metal supported electro-chemical device cells with metal supports on both anode and cathode sides, b). sealing the peripherals of porous cell layers with an electrically insulating sealing material such as glass. c). bonding the cells and interconnects through commonly used metal-to-metal bonding methods, such as brazing or laser welding.

Various embodiments disclose a glow plug for a solid oxide fuel cell system. The glow plug includes a housing having a first end portion and a second end portion. The glow plug includes a heating element longitudinally disposed in the housing, extending from the second end portion of the housing towards the first end portion and extending outwardly from the housing for igniting fuel. Further, the glow plug includes a pair of coiled wires electrically connected to the heating element. Further, the glow plug includes a potting compound disposed within the second end portion of the housing for securing electrical coupling of the pair of coiled wires with the heating element. Furthermore, the glow plug includes a sealing element configured to form an air-tight connection between the housing and the heating element. The sealing element is positioned on top of the potting compound.

Various embodiments disclose a glow plug for a solid oxide fuel cell system. The glow plug includes a housing having a first end portion and a second end portion. The glow plug includes a heating element longitudinally disposed in the housing, extending from the second end portion of the housing towards the first end portion and extending outwardly from the housing for igniting fuel. Further, the glow plug includes a pair of coiled wires electrically connected to the heating element. Further, the glow plug includes a potting compound disposed within the second end portion of the housing for securing electrical coupling of the pair of coiled wires with the heating element. Furthermore, the glow plug includes a sealing element configured to form an air-tight connection between the housing and the heating element. The sealing element is positioned on top of the potting compound.

An oxide ion conductor has a X.sub.3Z.sub.2(TO.sub.4).sub.3 structure, where X is a divalent metal element, Z is a trivalent metal element, and T is a tetravalent metal element, and has a composition expressed by (X.sub.1-xA.sub.x).sub.3(Z.sub.1-yB.sub.y).sub.2(T.sub.1-zC.sub.z).sub.3O.sub.12+δ where the element X is Ca, Fe, Gd, Ba, Sr, Mn, and/or Mg, the element Z is Al, Cr, Fe, Mn, V, Ga, Co, Ni, Ru, Rh, and/or Ir, the element T is Si and/or Ge, an element A is La, Pr, Nd, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Lu, and/or Sr, an element B is Zn, Mn, Co, Ru, and/or Rh, and an element C is Si, Al, Ga, and/or Sn, 0≤x≤0.2, 0≤y≤0.2, and 0≤z≤0.2 are satisfied, and δ is a value securing electrical neutrality.

An oxide ion conductor has a X.sub.3Z.sub.2(TO.sub.4).sub.3 structure, where X is a divalent metal element, Z is a trivalent metal element, and T is a tetravalent metal element, and has a composition expressed by (X.sub.1-xA.sub.x).sub.3(Z.sub.1-yB.sub.y).sub.2(T.sub.1-zC.sub.z).sub.3O.sub.12+δ where the element X is Ca, Fe, Gd, Ba, Sr, Mn, and/or Mg, the element Z is Al, Cr, Fe, Mn, V, Ga, Co, Ni, Ru, Rh, and/or Ir, the element T is Si and/or Ge, an element A is La, Pr, Nd, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Lu, and/or Sr, an element B is Zn, Mn, Co, Ru, and/or Rh, and an element C is Si, Al, Ga, and/or Sn, 0≤x≤0.2, 0≤y≤0.2, and 0≤z≤0.2 are satisfied, and δ is a value securing electrical neutrality.

A thermally integrated hotbox apparatus combining a steam reformer, a plurality of solid oxide fuel cell (SOFC) stacks, a plurality of oxidant manifolds, and at least one heat extractor. The steam reformer occupies a central position in the hotbox, around which are disposed in spaced-apart relation a plurality of SOFC stacks. A burner may be associated with the steam reformer, either within or outside the hotbox. An oxidant manifold is disposed between each pair of adjacent SOFC stacks. A heat exchanger is incorporated between an SOFC stack and an oxygen manifold. The hotbox design optimally captures thermal heat from the SOFC stacks for use in producing steam and operating the endothermic steam reformer. The apparatus reduces duty cycle of the burner, which produces heat and steam needed for operation of the endothermic steam reformer.

A thermally integrated hotbox apparatus combining a steam reformer, a plurality of solid oxide fuel cell (SOFC) stacks, a plurality of oxidant manifolds, and at least one heat extractor. The steam reformer occupies a central position in the hotbox, around which are disposed in spaced-apart relation a plurality of SOFC stacks. A burner may be associated with the steam reformer, either within or outside the hotbox. An oxidant manifold is disposed between each pair of adjacent SOFC stacks. A heat exchanger is incorporated between an SOFC stack and an oxygen manifold. The hotbox design optimally captures thermal heat from the SOFC stacks for use in producing steam and operating the endothermic steam reformer. The apparatus reduces duty cycle of the burner, which produces heat and steam needed for operation of the endothermic steam reformer.

A method of forming an interlayer of a solid oxide cell unit on the surface of a substrate may include: providing a base interlayer solution comprising a solution of a soluble salt precursor of a metal oxide (crystalline) ceramic and crystalline nanoparticles, depositing the base interlayer solution onto the surface of the substrate, drying the base interlayer solution to define a nanocomposite sub-layer of the soluble salt precursor and nanoparticles, heating the sub-layer to decompose it and form a film of metal oxide comprising nanoparticles on the surface, and firing the substrate with the film on the metal surface, to form a nanocomposite crystalline layer.

A fuel cell system including: an electrochemical pump including a first anode, a first cathode, and a first electrolyte membrane including a proton conductive oxide, the electrochemical pump separating hydrogen from a gas containing the hydrogen, and a solid oxide fuel cell that includes a second anode, a second cathode, and a second electrolyte membrane including a solid oxide electrolyte, and that generates electricity by reacting a fuel gas and an oxidant gas with each other.

A fuel cell system including: an electrochemical pump including a first anode, a first cathode, and a first electrolyte membrane including a proton conductive oxide, the electrochemical pump separating hydrogen from a gas containing the hydrogen, and a solid oxide fuel cell that includes a second anode, a second cathode, and a second electrolyte membrane including a solid oxide electrolyte, and that generates electricity by reacting a fuel gas and an oxidant gas with each other.