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The effects of doping manganese ions into a cerium oxide lattice for a thermochemical two-step water-splitting cycle to produce oxygen and hydrogen and new synthesis methods were experimentally investigated. In order to comparison of oxygen/hydrogen producing performance, pristine CeO2, a coprecipitation method for Mn-CeO2, and a direct depositing method for Mn-CeO2 with different particle sizes (50~75, 100–212, over 212 μm) and doping extents (0, 5, 15 mol%) were tested in the context of synthesis and fabrication processes of reactive metal oxide coated ceramic foam devices. Sample powders were coated onto zirconia (magnesium partially stabilized zirconia oxide, MPSZ) porous foam at 30 weight percent using spin coating or a direct depositing method, tested using a solar reactor at 1400 °C as a thermal reduction step and at 1200 °C as a water decomposition step for five repeated cycles. The sample foam devices were irradiated using a 3-kWth sun-simulator, and all reactive foam devices recorded successful oxygen/hydrogen production using the two-step water-splitting cycles. Among the seven sample devices, the 5 mol% Mn-CeO2 foam device, that synthesized using the coprecipitation method, showed the greatest hydrogen production. The newly suggested direct depositing method, with its contemporaneous synthesis and coating of the Mn-CeO2 foam device, showed successful oxygen/hydrogen production with a reduction in the manufacturing time and reactants, which was lossless compared to conventional spin coating processes. However, proposed direct depositing method still needs further investigation to improve its stability and long-term device durability.

Development of Synthesis and Fabrication Process for Mn-CeO2 Foam via Two-Step Water-Splitting Cycle Hydrogen Production