The Solid Oxide Fuel Cell—
Extending Fossil Fuels

Solid Oxide Fuel Cells (SOFCs) can provide clean, electrical energy to power everything from the family SUV to remote military installations. Their fuel flexibility—running on both hydrogen and fossil fuels—efficiently uses a vehicle’s fuel supply to provide consumer- comfort extras like mini-refrigerators and video systems without running the engine. However, high manufacturing costs and less-than-ideal reliability keep them from being the immediate answer to our nation’s critical energy problems.

Scientists at Pacific Northwest National Laboratory are developing materials and techniques used to fabricate solid oxide fuel cells. The button cell test is used for screening electrode materials for solid oxide fuel cells. The data obtained from button cell tests are used to select electrode materials for full-sized cells. A PNNL researcher configured the test set-up to analyze the electrochemical characteristics of electrode materials.

The U.S. Department of Energy (DOE) has formed a unique collaboration between industry and research organizations to address the issue. The Solid State Energy Conversion Alliance (SECA) is enlisting varied approaches to develop a solid oxide fuel cell to meet DOE’s cost and performance goals and their own business needs. SECA is coordinated by Pacific Northwest National Laboratory, operated by Battelle, and the National Energy Technology Laboratory.

Because of high costs, Gary McVay, PNNL’s manager in SECA, says, “We are working on a modular fuel cell design that can be customized for specific applications, and then mass produced. Our fuel cells will be adapted to provide power for land-based, transportation, and military applications.”

SECA has two components, beginning with a Core Technology Program to address technical challenges and share results among commercial partners interested in developing SOFCs. The second component is the collection of six commercial teams, each taking their own approach to develop and commercialize SOFCs for specific applications.

SECA has made impressive gains in the first stage of their Core Technology Program, predictive modeling. The saved money and time have furthered SECA’s goal to make affordable SOFCs. “As SECA moves into the pre-commercialization phase, we’ll refine our modular fuel cell design to make it easily customized, more affordable and more reliable,” McVay said. When the SECA Program moves to the commercialization stage, cost-sharing will shift from 80% government, 20% industry to 50% government, 50% industry. This shift will better reflect the commercialization and potential profits of the technology.

Several national energy programs are also working with SECA SOFCs.

• FutureGen aims to produce electricity from fossil fuels with near-zero emissions and to supply hydrogen to meet national energy needs.
• DOE’s 21st Century Truck Program is exploring SECA fuel cells that produce electricity for essential power systems to increase overall efficiency, operate over a range of temperatures and reduce emissions from idling engines.
• U.S. Department of Defense is developing fuel cells to work with military fuels for a multitude of mobile applications, they must be quieter than generators and hold up in harsh environments.

Battelle sees the SECA collaboration as a key in extending the use of fossil fuels and reducing the nation’s dependence on imported oil. While SECA works to remove technology and economic challenges facing widespread use of fuel cells, the collaborators’ research will drive the fuel cells of tomorrow.

For additional information, please contact Dr. Gary McVay, (509) 375-3762, gary.mcvay@pnl.gov.