Solid oxide fuel cells are a very efficient and clean method of power generation, but to be commercially viable, significant cost reduction is necessary to reduce the cost of power generated. The stack reformer packaging in tubular solid oxide fuel cells is expensive because it is comprised of machined high alumna ceramic fiber board, costing over $88,000 for a 100 kilowatt unit. This project will replace the current machined fiberboard with a much more economical ceramic particulate material, and develop near-net-shape ceramic technology to form the new ceramic into the appropriate shapes. Phase I developed a fine-grained ceramic particulate-based material that was then formed with a unique process into an economical prototype outer-stack reformer-board shape for tubular solid oxide fuel cells. Over 40 ceramic material compositions were formulated and characterized, to achieve targeted properties including no detectable crystalline silica content and reasonable strength. In Phase II, the ceramic composition data and small scale process techniques will be used as the basis for ceramic material optimization and prototype production of full size, large, complex ceramic shapes for use in tubular solid oxide fuel cell packages. The structural refractory design of the entire fuel cell package will also be reviewed by a major fuel cell manufacturer, followed by design of near-net shape ceramic components for optimum economy in shape manufacture and package assembly, without sacrificing cell performance.
Commercial Applications and Other Benefits as described by the awardee: The technology should have application in tubular solid oxide fuel cells where significant savings in the cost of currently-used, machined ceramic fiber boards should be achieved. Savings of at least $55,000 (65 percent) per 100 kilowatt fuel cell unit should be attained with ceramic particulate-based shapes, resulting in a reduction in the cost of power generated.
