Ultra-High Power Density Metal Supported SOFC Stack for High Efficiency Propulsion and Power Systems

This Phase I SBIR OSD project proposes the development and testing of a porous metal anode-supported intermediate-temperature solid oxide fuel cell (PMS-IT-SOFC) that exhibits high electrochemical efficiency, high degree of fuel utilization (reformed JP-8, diesel, or dodecane), and low operating temperature characteristics intended for high efficiency, logistic-fueled propulsion and power systems for small autonomous vehicles and mobile power generation and other commercial users. The proposed cell design operates at a lower temperature of 600-800°C (as compared to 800-1000°C for conventional SOFC cells) at 0.55 V, 4.60 amp/cm2, and producing a maximum power density of 2.5 W/cm2. The unit cell design is light resulting in cell stack configuration that produces 2000 W/kg requiring approximately 1000 W/L, including fuel and oxidant supplies as well as balance of plant components. Reliable cell performance is intended to endure at least 10,000 hours of operation before a major overhaul is required. The PMS-IT-SOFC technology to be developed is intended for quick scale up to plant-scale production after Phase II project execution. The innovative design for the PMS-IT-SOFC fuel cell makes use of a highly conductive porous metal anode manufactured using MER"s powder metallurgy technology, a highly ionic conductor electrolyte, and a very efficient cathode.