SBIR-STTR Award

ITN proposes to create an innovative anode supported membrane electrode assembly (MEA) for solid oxide fuel cells (SOFCs) that is capable of long-term operation at low temperature by the direct oxidation of dry methane or syngas fuel without coke formation on the anode. ITN's MEA is more efficient, durable, reliable, versatile and economical than the state of the art because it is made with transformative manufacturing techniques – microwave sintering and energy optimized plasma deposition (EOPD). The proposed fuel-flexible, direct oxidation MEA is capable of power densities up to 2 W/cm2 at 600?C. ITN's EOPD of thin, conformal YSZ electrolytes creates a stress free interface between the anode and electrolyte which improves MEA durability, cycle-ability and cell performance. The MEAs produced in this research effort can be incorporated into SOFC stacks capable of producing power in the 1-3 kW range. Because the fuel is oxidized directly in the SOFC, without external fuel processing, the thermodynamic efficiencies from fuel source to DC output exceed 70%. Higher efficiencies translate to minimal cooling required as obtained by way of conduction through the stack to a radiator exposed to space and/or by anode exhaust flow.

The proposed innovation builds on the successes of the Phase I program by integrating our direct oxidation membrane electrode assembly (MEA) into a monolithic solid oxide fuel cell stack (SOFC) capable of long-term operation on methane or syngas. This innovation is significant because it will contribute to durable, cycle-able simple SOFC systems to meet the needs for NASA and commercial customers.ITN's Phase II strategy addresses the technical hurdles that limit the long-term durability and thermal cycling of state-of-the-art SOFCs operating on methane fuel, including�Matching stack components for coefficient of thermal expansion�Reducing stack mass�Stack sealing�Reducing anode degradation, and�Reducing operating temperatures.With this innovation, we project that the proposed SOFC stack will be capable of operating without degradation for more than the targeted 2500 hours and will operate without power density degradation after 50 start-up and shut-down cycles. By utilizing the direct-oxidation membrane electrode assemblies developed in the phase I program, the thermodynamic efficiencies from fuel source to DC output should exceed 70%. Higher efficiencies translate to lower cooling requirement as obtained by way of conduction through the stack to a radiator exposed to space and/or by anode exhaust flow.