Open Competition - Advanced Materials/Chemicals (October 2000)

Self-Propagating High-Temperature Synthesis Of Solid Oxide Fuel Cell Cathode Material

Sponsor: Blasch Precision Ceramics, Inc.

• Project Performance Period: 4/1/2001 - 3/31/2004
• Total project (est.): $2,133,057.00
• Requested ATP funds: $1,734,193.00

Fuel cells convert fuels such as natural gas into electricity through non-combustion, electrochemical reactions. They are efficient, relatively non-polluting (water is a principle by-product) and can provide clean, reliable stand-alone electric power and heat without problems of blackouts. Solid-oxide fuel cells (SOFCs) are one of the most attractive designs because of their high-efficiency solid-state design and the potential to use various types of fuel, but the high cost of producing the special ceramic cathode materials used in the cell is a major drawback. Blasch Precision Ceramics proposes a novel manufacturing technology that could dramatically reduce this cost. A variety of methods can now be used to produce the ceramic materials, but they are either energy-intensive and time-consuming or produce a variety of undesirable by-products. None are cost-effective. Blasch's alternative is simple in concept but technically daunting -- finely powdered components are mixed and pressed into a cylinder, and one end is ignited. In a phenomenon called "solid flame", the mixture combusts, but the product remains a solid. The solid flame moves down the cylinder, creating the product as it goes. This process is called self-propagating high-temperature synthesis (SHS), and has been used abroad to produce several commercial products such as refractories or abrasives. This project represents the first attempt to use SHS to produce commercial quantities of the complex oxides used in SOFC. The project is risky because there are many process variables and almost no available data, which has detered private investment. If initial small-batch trials are successful, Blasch intends to push the technology even further by building a prototype continuous-process SHS facility in which a constant stream of reactants feeds the progressing combustion front producing a constant stream of the solid oxide -- using containment that can withstand the 1800 degrees Celsius reaction temperature. Because the process is fast, uses little added energy and has no environmentally harmful emissions, Blasch anticipates being able to produce SOFC cathode materials at a fraction of the current cost. As a result, the cost of SOFC cathode units could be cut by more than half, dramatically reducing the overall cost of SOFC installations and enabling more widespread use of the technology.

For project information:

Dr. David A. Larsen, (518) 436-1263
dlarsen@blaschceramics.com

ATP Project Manager

Richard Bartholomew, (301) 975-4786
richard.bartholomew@nist.gov