SOLID-OXIDE FUEL CELLS

Responding to worldwide demand for off-grid power and energy security

The solid oxide fuel cell (SOFC) is an electrochemical cell that converts fuel chemical energy directly into electricity. SOFC systems operate at high temperatures, which enables very high electrical efficiency and stable, continuous power output. This makes the technology attractive for stationary power where uptime and efficiency matter.

Typical uses for SOFC technology are combined heat & power for homes and industry, primary and backup power for critical facilities like data centers, and for power in marine and other heavy transport applications. For demanding data centers, e.g., for AI computing, securing new grid capacity can take years and on-site SOFC power generation helps reduce dependency on long grid connection lead times.

A key advantage of SOFC is fuel flexibility. Commercial systems are available that run on broadly available fuels such as natural gas or biogas, with higher efficiency and lower emissions than gas turbines. That flexibility supports deployment across regions with different infrastructure and fuel availability. When operated with pure hydrogen as fuel, the only products are electricity, water, and heat.

A single SOFC is built from ceramic components and generates a limited amount of power. For practical applications, multiple cells are assembled into stacks, which form the core of an SOFC system. Within the stack, metallic interconnects provide the electrical connection between cells and keep the fuel and air gas flow separated. The integrity of the interconnects is central to performance, durability, and manufacturability.

In demanding operation, SOFC stacks must withstand long exposure to oxidizing environments while maintaining low electrical resistance and stable interfaces. High temperature coating solutions with PVD are used to protect the components from degradation, and are an important part of delivering durable, consistent SOFC performance.

Why PVD technology for fuel cells

• Corrosion Resistance: PVD coatings provide excellent protection against corrosion, which is crucial for the longevity and efficiency of fuel cells.
• Improved Conductivity: The coatings enhance the electrical conductivity of bipolar plates and interconnects, which is essential for efficient energy transfer within the fuel cell.
• Durability: PVD coatings are highly durable and can withstand the harsh operating conditions of fuel cells, including high temperatures and chemical exposure.
• Cost-Effectiveness: PVD technology can reduce material costs by enabling less expensive base materials while achieving high performance.
• Environmental Benefits: PVD processes are generally more environmentally friendly compared to other coating methods, as they produce fewer hazardous by-products.