Ceramic fuel cells offer a clean and efficient means of producing electricity through a variety of fuels. However, miniaturization of cell dimensions for portable device application remains a challenge, as volumetric power densities generated by readily-available planar/tubular ceramic cells are limited. Here, we demonstrate a concept of ‘micro-monolithic’ ceramic cell design. The mechanical robustness and structural integrity of this design is thoroughly investigated with real-time, synchrotron X-ray diffraction computed tomography, suggesting excellent thermal cycling stability. The successful miniaturization results in an exceptional power density of 1.27 W cm⁻² at 800 °C, which is among the highest reported. This holistic design incorporates both mechanical integrity and electrochemical performance, leading to mechanical property enhancement and representing an important step toward commercial development of portable ceramic devices with high volumetric power (>10 W cm⁻³), fast thermal cycling and marked mechanical reliability.

Mass transport can significantly limit the rate of reaction and lead to concentration polarisation in electrochemical devices, especially under the conditions of high operating current density. In this study we investigate hierarchically structured micro-tubular solid oxide fuel cells (MT-SOFC) fabricated by a phase inversion technique and quantitatively assess the mass transport and electrochemical performance improvement compared to a conventional tubular SOFC. We present pioneering work to characterise the effective mass transport parameters for the hierarchically porous microstructures by an integrated computed fluid dynamics simulation, assisted by multi-length scale 3D X-ray tomography. This has been historically challenging because either imaging resolution or field of view has to be sacrificed to compensate for the wide pore size distribution, which supports different transport mechanisms, especially Knudsen flow. Results show that the incorporation of radially-grown micro-channels helps to decrease the tortuosity factor by approximately 50% compared to the conventional design consisting of a sponge-like structure, and the permeability is also improved by two orders of magnitude. When accounting for the influence of Knudsen diffusion, the molecule/wall collisions yield an increase of the tortuosity factor from 11.5 (continuum flow) to 23.4 (Knudsen flow), but the addition of micro-channels helps to reduce it down to 5.3. Electrochemical performance simulations using the measured microstructural and mass transport parameters show good agreement with the experimental results at elevated temperatures. The MT-SOFC anode displays 70% lower concentration overpotential, 60% higher power density (0.98 vs. 0.61 W cm⁻²) and wider current density window for maximum power density than the conventional design.

Herein, results of combined greenhouse gas treatment with clean energy conversion is reported for the first time. Multi-channel tubular SOFCs were operated with N₂O instead of air as the oxidant leading to a 50% increase in power density. Techno-economic evaluation suggested the feasibility of the combined approach eliminating the cost penalty for N₂O abatement.