The Solid State Energy Conversion Alliance (SECA) was initiated in the fall of 1999 bringing together government, industry, and the scientific community to promote the development of environmentally friendly solid oxide fuel cells (SOFC) for a variety of energy needs. SECA is an alliance of industry groups who individually plan to commercialize SOFC systems for pre-defined markets; research and development institutions involved in solid-state development activities; and government organizations that provide funding and management for the program. The SECA alliance was formed to accelerate the commercial readiness of SOFCs in the 3 kW to 10 kW for use in stationary, transportation, and military applications. This partnership between the U.S. industry, universities, and other research organizations represents a new model for joint government and private industry technology research and development, and also provides an effective use of funding resources, which is critical to the success of the SECA Program.
SECA Fuel Cell Stacks Meet, Surpass DOE Goals
Two fuel cell stacks developed by FuelCell Energy (FCE) in partnership with Versa Power Systems achieved 5,000 hours of service in February, meeting a goal of the U.S. Department of Energy's Solid State Energy Conversion Alliance (SECA)."
SECA Fuel Cell Program Selects Two Projects
The Department of Energy has selected two projects for the Department's Solid State Energy Conversion Alliance Program portfolio.
DOE Selects Projects to Advance Fuel Cell Technology
DOE has selected nine projects to join the Solid State Energy Conversion Alliance Core Technology Program portfolio that will address specific challenges in scaling up and integrating solid oxide fuel cells into advanced central generation power plants.
U.S. Navy Tests SECA SOFC Stacks
The Naval Undersea Warfare Center (NUWC) Division Newport is providing independent testing and evaluation of solid oxide fuel cell (SOFC) stacks being developed under DOE’s Solid State Energy Conversion Alliance (SECA) program. This testing targets SOFC performance under extreme conditions as expected in Unmanned Undersea Vehicles (UUVs), which must operate in an air-free environment. The Navy awarded a contract to purchase two, 10-cell SOFC stacks for independent testing and evaluation from Delphi Corporation on November 19, 2007. Delphi is a SECA Industry Team partner. NUWC has previously tested SOFC stacks developed by other SECA Industry Teams.
SECA fuel cells are ideal for use in central generation applications, enabling high efficiency, diverse opportunities for carbon capture (e.g., post-power block) and lower criteria pollutant emissions (e.g., less than 0.5ppm NOx, regardless of fuel). Integrated Gasification Fuel Cell (IGFC) system configurations utilizing near-term gasification and syngas cleaning technologies will generate power from coal with overall efficiencies of greater 45 to 50 percent (HHV, coal to AC power) or more, including the coal gasification and CO2 capture processes. In conjunction with SECA-driven fuel cell cost reduction, these IGFC systems will enable the clean, efficient and cost-effective use of the nation’s most abundant fossil fuel.
During the development of SECA SOFCs, technological spinoffs of SOFCs into a variety of other applications and markets are expected. This will increase SOFC manufacturing production volume and lower SOFC cost. One of these important application areas is the Department of Defense where SOFCs are being targeted by the U.S. Navy as power sources for UUVs because they offer rapid refueling capability, operation with logistics fuel, and high electric conversion efficiency (greater than 50% based on the lower heating value of fuel).
In addition, SOFC operation on pure oxygen instead of air, as in this UUV application, is a potentially interesting aspect of SOFC performance. Oxygen-blown coal gasifier systems could be designed to provide pure oxygen feed to a SOFC power plant block. Understanding SOFC performance under these conditions will be useful in the design of future high-efficiency IGFC plants.
SECA Fuel Cell Development Program Completes Phase I
Six industry teams have successfully completed tests of the first solid oxide fuel cell prototypes that can be manufactured at costs approaching those of conventional stationary power-generation technology. Part of the U.S. Department of Energy's Solid State Energy Conversion Alliance (SECA) program, these results reflect considerable progress towards commercially-viable solid oxide fuel cell (SOFC) systems. (5/07)
FuelCell Energy and Versa Power Successfully Complete
SECA
Phase I Solid Oxide Fuel Cell Program Six Months Early FuelCell Energy and Versa Power Systems announced the successful completion of Phase I performance and endurance tests on a prototype 3 to 10 kilowatt (kW) fuel cell commissioned by the U.S. Department of Energy (DOE) six months ahead of schedule. Two of the main major objectives of the Phase I development effort were to demonstrate the performance of a 3-10 kW prototype SOFC system and to develop factory cost estimates showing such systems could be manufactured on a cost-effective basis. Based on tests conducted by Versa Power and FuelCell Energy over a 2,100-hour operational period, the prototype successfully met all DOE-specified targets. These areas included power output, system efficiency, system availability and overall system endurance. System cost calculations also met the DOE's target. Subsequently, the prototype was shipped to the DOE's National Energy Technology Laboratory in Morgantown, WV for another 1,600 hours of testing. Both the initial system performance tests and the factory cost estimate were audited and confirmed by independent third party consultants approved by the DOE. (4/07)
Arcomac Makes Advances in Interconnect Coatings Interconnect development is a primary focus of the SECA Core Technology Program. Arcomac Surface Engineering, LLC significantly enhanced oxidation resistance, exhibited negligible Cr volatility, and showed low, stable area specific resistance (ASR) during over 1000 hours of testing of interconnect protective coatings on standard 430SS samples. The 430SS interconnect sample also demonstrates substantial improvements, showing inhibited silicon oxide formation with Arcomac coating. This system design also would lower the cost of coating to $2.80 per plate manufactured, a 50% decrease from current costs, with future possibilities that could reduce the cost to ~$1 or less per plate. These interconnect advances improve the lifetime and cost of SOFC systems, helping to meet the SECA cost and efficiency goals by 2010. (4/07)
SUNY Albany Develops Sensor for SOFC SUNY Albany is investigating the feasibility of an innovative chemical sensor based on nano-cermet Surface Plasmon Resonance (SPR) bands that could be integrated with a solid oxide fuel cell (SOFC). The sensor is directly integrated in the SOFC and would allow for the real time monitoring of the operating temperature in the SOFC stack, the fuel concentrations and the detection of impurities in the fuel (such as Sulfur). The research has determined the role of O2 in the sensing mechanism, while also characterizing CO detection properties and H2 sensing properties on the film. The sensor technology, which can withstand the demanding conditions in the fuel cell, will allow for quicker response to operating conditions and more efficient operation of the SOFC. (4/07)
Eltron Makes Strides in Fuel Reformation Eltron Research is developing self-cleaning reformer walls designed to suppress deposition of carbon in the cool zones of diesel fuel reformers. Carbon formation can hinder performance and efficiency by coating the walls and plugging the fuel reformer and limiting catalyst options. The reformer walls are being coated with oxidation catalysts, which diffuse oxygen from the outer to inner walls of the reformer, helping to eliminate carbonaceous layers. Tests have determined temperature and composition range for successful operation, with temperatures ranging from 300oC and an oxygen-to-carbon ratio of 2.61:1 to 1000oC and oxygen-to-carbon ratios of 1.02:1. (3/07)
Efficiency Goal Exceeded in Power Electronics Technology Development
Working in cooperation with NETL under FE’s Solid State Energy Conversion Alliance (SECA) Fuel Cell program, researchers at Virginia Tech decreased the turn-off losses in the solid state switching feature of a device that boosts the relatively low direct current voltage produced by solid oxide fuel cell stacks to the higher voltage needed for conversion to alternating current for general usage. Employing advanced high power solid state switches with high efficiency soft-switching and high performance digital control techniques, the V6™ can now convert 50 volts to 400 volts with energy efficiency greater than 97 percent. Such energy-efficient power electronics technology reduces fuel consumption as well as the size of fuel cell systems, helping to meet the 60 percent efficiency target and the $400/kW cost target of the SECA Program by 2010. (2/07)
Siemens achieves major milestone in Solid Oxide Fuel Cell program
Siemens Power Generation announced the successful testing of its latest solid oxide fuel cell (SOFC) technology that incorporates its high power density technology being developed under the U. S. Department of Energy’s (DOE) Solid State Energy Conversion Alliance (SECA). A prototype 5 kW-class complete system using the SECA technology has operated for 2,800 hours and continues to operate at the Siemens facility near Pittsburgh, PA. It has met or exceeded all of the DOE technical and economic objectives for Phase 1 of the SECA program. (11/06)
FuelCell Energy and U.S. Department of Energy Finalize Award to Develop Clean Coal-Fueled Multi-Megawatt Solid Oxide Fuel Cell System FuelCell Energy, Inc. (NasdaqNM:FCEL), a leading manufacturer of ultra-clean and efficient electric power generation plants for commercial, industrial and government customers, today announced it has finalized terms with the U.S. Department of Energy (DOE) for a $36.2 million Phase I award to develop a coal-based, multi-megawatt solid oxide fuel cell-based hybrid system. This award provides funding for the first stage of the 10-year, three-phased Fuel Cell Coal-Based Systems project, part of the DOE Office of Fossil Energy's Solid State Energy Conversion Alliance (SECA). Total project funding for this and the other two planned phases is anticipated to be approximately $180 million. (10/06)
Four Minority Universities Selected for Fossil Energy Research Grants Researchers at the University of Texas at San Antonio will fabricate low-temperature solid oxide fuel cells out of novel electrode and electrolyte materials and determine the structure-performance relationship of these materials. (10/06)
GE and Delphi Meet Stack Cost Goal
SECA Industry Team participants Delphi and GE have made significant advances in the reduction of solid oxide fuel cell (SOFC) stack costs, surpassing the SECA target for 2006. The estimated costs were $294/kW for a 4.24kW Delphi system; and $254/kW for a 5.4kW GE system. Both teams easily bettered the GPRA SECA goal of <$300/kW. Meeting this latest target puts both Delphi and GE on track towards meeting the SECA goal of <$400/kW system cost. (4/06)
Siemens Power Generation Develops Low Cost Cathode Material
Siemens Power Generation recently developed an alternative cathode composition (LSM based) that is being evaluated through cell testing. Initial results show acceptable cell properties and performance, with material costs approximately 10 percent lower than that of present composition. This is very significant because over 95 percent of the cell material is cathode. These advancements put Siemens Power Generation in position to meet the SECA Phase I milestones and continue towards meeting the final SECA goal of producing a $400/kW solid oxide fuel cell. (2/06)
Delavan
Delavan recently completed testing of its statistical design-of-experiment study investigating fuel injector operating variables, finding a strong correlation between air supply pressure and mixture uniformity. This discovery allows Delavan to determine the minimum requirement for injector supply pressure of the devices, a significant step in design of the injector system. Along with this breakthrough, Delavan also has applied for a patent for their preheating injector. These developments have Delavan nearing the start of Phase II of the project, creating fuel injection devices for SECA Industry team SOFCs. (1/06)
Significant Milestone Achieved in SECA Fuel Cell Development Program
A prototype of the first fuel cell capable of being manufactured at a cost approaching that of conventional stationary power technology has been successfully tested as part of the U.S. Department of Energy's Solid State Energy Conversation Alliance (SECA) program. (1/06)
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