Open Competition - Electronics/Computer Hardware/Communications (October 2000)

Integrated Planar Solid Oxide Fuel Cell Stack Development

Sponsor: ITN Energy Systems, Inc.

• Project Performance Period: 11/1/2000 - 10/31/2003
• Total project (est.): $3,983,463.00
• Requested ATP funds: $1,996,463.00

Utility deregulation; concerns about dependence on foreign energy sources; and inefficient, polluting fossil fuel power plants are combining to increase the attraction of small independent generators that supply electricity for individual buildings, complexes, or neighborhoods. While conventional technologies provide reliable and cost-effective energy sources, a far more efficient, less-polluting alternative is innovative types of fuel cells -- devices that generate electricity through electrochemical reactions between hydrogen and oxygen. Even the heat generated by fuel cells can be put to work, to warm buildings and heat water, or to drive small steam-turbine generators. Perhaps the most promising technology being developed is the solid-oxide fuel cell (SOFC). ITN Energy Systems proposes to develop a new kind of solid-oxide cell that operates at lower temperatures than existing solid-oxide devices. These new reduced-temperature SOFCs offer the potential for higher power density, lower cost, and increased operating life. The lower operating temperature means that expensive ceramic electrical connections inside the cells can be replaced with lower-cost metal connections, which are better conductors than ceramics, reducing energy loss from electrical resistance. ITN Energy Systems is teaming up with the Idaho National Engineering and Environmental Laboratory (Idaho Falls, Idaho), the University of Colorado at Boulder, and the Colorado School of Mines (Golden, Colo.). The new cells will feature a novel five-layer design in which metal contacts are deposited with a low-cost "thermal spray" technique, and a process for making airtight channels inside the cells will eliminate leaking seals that have plagued conventional designs. The cells then will be "stacked" on top of each other, and the number of cells in a stack will depend on how much power is needed. Although ITN has received interest and partial support for the project from the Tucson Electric Power Co., TEP is unable to finance all of the work due to the high technology risk associated with this project. ATP support will enable ITN to address the technical barriers and dramatically speed up development of the technology so that it is ready in time to meet the emerging markets.

For project information:

William G. Barker, (303) 420-3646
wbarker@itnes.com

ATP Project Manager

Gerald Castellucci, (301) 975-2435
gerald.castellucci@nist.gov