Scalable processes for fabrication of intermediate temperature solid oxide fuel cell stacks for auxiliary power units

To develop intermediate temperature solid oxide fuel cell (it-sofc) technology addressed to the automotive and energy sector. Special attention will be paid in massive synthesis of non-conventional materials and scalability of manufacturing processes for cells and interconnects.

The main goal of the project is to develop new scalable fabrication processes for manufacturing novel Intermediate Temperature Solid Oxide Fuel Cells (IT-SOFC) fueled with hydrogen or methane for Auxiliary Power Units (APU). It is also the goal of this project to develop an emergent technology, specially addressed to the automotive to provide this sector with tools to compete in international markets and attract international investment from both private and public sources (by participation in competitive international Framework Program, JTIs, etc). In particular, the project will open new lines of business for the three industrial partners of the consortium, FAE, KCERACELL and AMES, and will increase the know-how and international visibility of IREC, the involved research center. The main technological objectives of this project are listed in the following: - Development and optimization of massive synthesis of ceramic powders in KCERACELL for manufacturing intermediate temperature solid oxide cells and interconnects (or coatings thereof). - Development and implementation of the manufacturing technology for intermediate temperature solid oxide fuel cells in the facilities of FAE. - Development and optimization of metal-based interconnects for IT-SOFCs in AMES. - Fabrication and test of SOFC stacks of 100W fueled with hydrogen, as a first stage of a further development of stacks up to 5kW. - Feasibility of the fabricated SOFCs for directly operation with methane (and other hydrocarbons). The proposed work plan consists in the next three main tasks: - Development and fabrication of IT-SOFCs fueled with H2 - Development and fabrication of IT-SOFCs with internal reforming of methane - Development of SOFC stacks fueled with H2 and CH4 The high-level outputs of the cells of the system developed will be: Working temperature: 700-800 ºC Power density: 400 mW/cm2 Fuel: H2 and CH4 Faradic efficiency > 40% Degradation rate <3%/1000h Due to the high level technical skills required for the implementation of the technology and fabrication of solid oxide fuel cells, the project will generate high quality jobs related to high-added-value products. Moreover, since the project deals with a core technology, it is expected to lead a driving effect on the value chain, promoting private investment in the manufacture of auxiliary components and leading to the creation of new companies which find, in the integration of such technology, new business opportunities. Remarkable examples could be found in advanced ceramic and metallic materials supply (AMES and KCERACELL participating in the project), development of power control, thermal management, gas management, cogeneration of heat and electricity, etc. It is also expected to mobilize investment of large multinational companies, positioned at the top of the value chain, which, although without own knowledge in SOFC technology, would intend to incorporate it as a novel technology in some of its business units (automotive, sustainable energy, energy storage, etc.). This project faces the development of a new complex technology that promotes a change in the value chain, has a huge potential market and, by the moment, only few international players. Since the development of this technology is not completely reached at an industrial level in Europe, it is expected that it will have a strong technological relevance and will allow opening new international markets. This project will situate the consortium within the incipient SOFC manufacturers group already existing at industrial level in Europe and worldwide. As a result of the project, it is expected to generate and start exploitation of different patents. Finally, the success of this project would be decisive to drive the development in a medium term of another strategic technology, the high Temperature electrolysis by SOEC, which applies for one of the key sectors according to the EU: the energy storage. Energy storage is considered a cornerstone in the current and future energy system. In particular, for future scenarios based on renewable energies and distributed electrical power generation, the capability of storing a large amount of energy will be crucial due to the high volatility and variability of renewable energy sources.
Project ID: 
8 736
Start date: 
Project Duration: 
Project costs: 
2 040 000.00€
Technological Area: 
Fuel cell, hydrogen production
Market Area: 
Alternative Energy

Raising the productivity and competitiveness of European businesses through technology. Boosting national economies on the international market, and strengthening the basis for sustainable prosperity and employment.