The overall goal of this U.S. Department of Energy (DOE) sponsored project is the development of solid oxide fuel cell (SOFC) cell and stack technology suitable for use in highly-efficient, economically-competitive central generation power plant facilities fueled by coal synthesis gas (syngas). This program incorporates the following supporting objectives: ? Reduce SOFC-based electrical power generation system cost to $700 or less (2007 dollars) for a greater than 100 MW Integrated Gasification Fuel Cell (IGFC) power plant, exclusive of coal gasification and CO<
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separation subsystem costs. ? Achieve an overall IGFC power plant efficiency of at least 50%, from coal (higher heating value or HHV) to AC power (exclusive of CO<
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compression power requirement). ? Reduce the release of CO2 to the environment in an IGFC power plant to no more than 10% of the carbon in the syngas. ? Increase SOFC stack reliability to achieve a design life of greater than 40,000 hours. At the inception of the project, the efforts were focused on research, design and testing of prototype planar SOFC power generators for stationary applications. FuelCell Energy, Inc. successfully completed the initial stage of the project by meeting the program metrics, culminating in delivery and testing of a 3 kW system at National Energy Technology Laboratory (NETL). Subsequently, the project was re-aligned into a three phase effort with the main goal to develop SOFC technology for application in coal-fueled power plants with >
90% carbon capture. Phase I of the Coal-based efforts focused on cell and stack size scale-up with concurrent enhancement of performance, life, cost, and manufacturing characteristics. Also in Phase I, design and analysis of the baseline (greater than 100 MW) power plant system?including concept identification, system definition, and cost analysis?was conducted. Phase II efforts focused on development of a ?25 kW SOFC stack tower incorporating multiple stack building blocks of scaled-up cells, suitable for integration into a large-scale fuel cell power module. Activities in Phase II also included the development of the baseline system, factory cost estimate for the baseline plant?s power block, and conceptual design of a natural gas fueled sub-MW system to be used for testing and verification of the fuel cell stacks in a system environment. The specific objective for Phase III was the validation of the performance and robustness of stacks and scaled stack arrays suitable for use in large-scale power generation systems such as an IGFC with reliable, fail-safe operation being of paramount importance. The work culminated in the verification tests of a 60 kW SOFC stack module in a power plant facility. This final technical report summarizes the progress made during the project period. Significant progress was made in the areas of cell and stack technology development, stack module design, sub-scale module tests, Baseline Power Plant system development and Proof-of- Concept Module unit design. The development of this technology will significantly advance the nation?s energy security and independence interests while simultaneously addressing environmental concerns, including greenhouse gas emissions and water usage.