Production of electrolyte membranes for ZEBRA batteries

ZEBRA batteries (Zero Emission Battery Research Activities), are one of the possible solutions to electrical storage for stationary applications due to their high energy and power density. These systems are based on nickel-sodium chloride cells operating at high temperatures (about 270-350°C), and that rely on a ceramic ?"-alumina tube or planar membrane as solid electrolyte. The ceramic process needed to produce the electrolytic compartment has a key role to enhance and adapt the batteries performances to the specific requirements for stationary regime applications. Each minimal composition or process deviation strongly influences the final properties of the device. Aim of this work was the ad-hoc study of the production process, from the powders synthesis to their forming and sintering needed to obtain ?"-alumina membranes with suitable morphological-structural characteristics. The research was deeply focused onto the analysis of the materials sintering behaviour, on the study of reactive sintering processes and on the influence of thermal treatments on the chemical-structural properties of the material. The optimization of the entire ceramic process leaded to the production of a full density material with chemical-microstructural properties suitable for high efficiency batteries.