CCS and Power Systems

Advanced Energy Systems - Solid Oxide Fuel Cells


SOFC Protection Coatings Based on a Cost-Effective Aluminization Process


Performer: NexTech Materials Ltd.

Project No: SC0008203


Program Background and Project Benefits

The U.S. Department of Energy (DOE) is developing the next generation of efficient fossil fuel technologies capable of producing affordable electric power with near-zero emissions. The Solid Oxide Fuel Cell (SOFC) program at DOE’s National Energy Technology Laboratory (NETL) is focused on developing low-cost, highly efficient SOFC power systems that are capable of simultaneously producing electric power, from either natural gas or coal, with carbon capture capabilities. Research is directed towards the technologies that are critical to the commercialization of SOFC technology. To successfully complete the development of SOFC technology from the present state to the point of commercial readiness, the SOFC Program efforts are aligned into three Key Technologies:

(1) Anode, Cathode, and Electrolyte (AEC) Development
(2) Atmospheric Pressure Systems
(3) Pressurized Systems

The AEC Development Key Technology is R&D in nature whereas the other two, Atmospheric Pressure Systems and Pressurized Systems, are focused on the development, demonstration, and deployment of SOFC power systems.

The AEC Development Key Technology consists of projects that will lead to substantially improved power density, enhanced performance, reduced degradation rate, and more reliable and robust systems. Research is focused on the technologies critical to the commercialization of SOFC technology, such as cathode performance, gas seals, interconnects, failure analysis, coal contaminants, fuel processing, and balance-of-plant components. Research is conducted at universities, national laboratories, small businesses, and other R&D organizations.

NexTech Materials Ltd. will build upon encouraging preliminary results to develop a commercially viable aluminization process that is amenable to high volume solid oxide fuel cell manufacturing. This work will leverage NexTech’s commercial process technology for applying conductive oxide protective coatings to ferritic steels – a process that has already been translated from the laboratory to pilot scale manufacturing at NexTech. It is anticipated that this experience will expedite commercialization of the aluminization process.


Project Details