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Production of a monolithic fuel cell stack with high power density

Author

Listed:
  • Stéven Pirou

    (Technical University of Denmark, Kgs)

  • Belma Talic

    (Technical University of Denmark, Kgs
    SINTEF Industry)

  • Karen Brodersen

    (Technical University of Denmark, Kgs
    Haldor Topsoe A/S, Kgs)

  • Anne Hauch

    (Technical University of Denmark, Kgs)

  • Henrik Lund Frandsen

    (Technical University of Denmark, Kgs)

  • Theis Løye Skafte

    (Technical University of Denmark, Kgs
    Noon Energy Inc.)

  • Åsa H. Persson

    (Technical University of Denmark, Kgs)

  • Jens V. T. Høgh

    (Technical University of Denmark, Kgs
    Haldor Topsoe A/S, Kgs)

  • Henrik Henriksen

    (Technical University of Denmark, Kgs)

  • Maria Navasa

    (Technical University of Denmark, Kgs
    Alfa Laval Lund AB, Energy Division)

  • Xing-Yuan Miao

    (Technical University of Denmark, Kgs)

  • Xanthi Georgolamprou

    (Technical University of Denmark, Kgs)

  • Søren P. V. Foghmoes

    (Technical University of Denmark, Kgs
    Esti Chem A/S)

  • Peter Vang Hendriksen

    (Technical University of Denmark, Kgs)

  • Eva Ravn Nielsen

    (Technical University of Denmark, Kgs
    Ramboll Group A/S)

  • Jimmi Nielsen

    (Technical University of Denmark, Kgs
    Radiometer Medical ApS)

  • Anders C. Wulff

    (Technical University of Denmark, Kgs)

  • Søren H. Jensen

    (Technical University of Denmark, Kgs
    DynElectro ApS)

  • Philipp Zielke

    (Technical University of Denmark, Kgs
    FOSS A/S)

  • Anke Hagen

    (Technical University of Denmark, Kgs)

Abstract

The transportation sector is undergoing a technology shift from internal combustion engines to electric motors powered by secondary Li-based batteries. However, the limited range and long charging times of Li-ion batteries still hinder widespread adoption. This aspect is particularly true in the case of heavy freight and long-range transportation, where solid oxide fuel cells (SOFCs) offer an attractive alternative as they can provide high-efficiency and flexible fuel choices. However, the SOFC technology is mainly used for stationary applications owing to the high operating temperature, low volumetric power density and specific power, and poor robustness towards thermal cycling and mechanical vibrations of conventional ceramic-based cells. Here, we present a metal-based monolithic fuel cell design to overcome these issues. Cost-effective and scalable manufacturing processes are employed for fabrication, and only a single heat treatment is required, as opposed to multiple thermal treatments in conventional SOFC production. The design is optimised through three-dimensional multiphysics modelling, nanoparticle infiltration, and corrosion-mitigating treatments. The monolithic fuel cell stack shows a power density of 5.6 kW/L, thus, demonstrating the potential of SOFC technology for transport applications.

Suggested Citation

  • Stéven Pirou & Belma Talic & Karen Brodersen & Anne Hauch & Henrik Lund Frandsen & Theis Løye Skafte & Åsa H. Persson & Jens V. T. Høgh & Henrik Henriksen & Maria Navasa & Xing-Yuan Miao & Xanthi Geor, 2022. "Production of a monolithic fuel cell stack with high power density," Nature Communications, Nature, vol. 13(1), pages 1-8, December.
    • Handle: RePEc:nat:natcom:v:13:y:2022:i:1:d:10.1038_s41467-022-28970-w
    DOI: 10.1038/s41467-022-28970-w
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    References listed on IDEAS

    as
    1. Zachary P. Cano & Dustin Banham & Siyu Ye & Andreas Hintennach & Jun Lu & Michael Fowler & Zhongwei Chen, 2018. "Batteries and fuel cells for emerging electric vehicle markets," Nature Energy, Nature, vol. 3(4), pages 279-289, April.
    2. Duan, Liqiang & Huang, Kexin & Zhang, Xiaoyuan & Yang, Yongping, 2013. "Comparison study on different SOFC hybrid systems with zero-CO2 emission," Energy, Elsevier, vol. 58(C), pages 66-77.
    3. Subodh Kharel & Bahman Shabani, 2018. "Hydrogen as a Long-Term Large-Scale Energy Storage Solution to Support Renewables," Energies, MDPI, vol. 11(10), pages 1-17, October.
    Full references (including those not matched with items on IDEAS)

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    Cited by:

    1. Wang, Xuan & Liu, Pengcheng & Ling, Zhi & Tian, Hua & Shu, Gequn, 2025. "Contribution of waste heat recovery system to hydrogen power technology for land transportation," Applied Energy, Elsevier, vol. 377(PA).
    2. Wang, Chen & He, Qijiao & Li, Zheng & Yu, Jie & Bello, Idris Temitope & Zheng, Keqing & Han, Minfang & Ni, Meng, 2024. "A novel in-tube reformer for solid oxide fuel cell for performance improvement and efficient thermal management: A numerical study based on artificial neural network and genetic algorithm," Applied Energy, Elsevier, vol. 357(C).
    3. Zhang, Zehui & He, Ningxin & Huo, Weiwei & Xu, Xiaobin & Sun, Chao & Li, Jianwei, 2025. "Privacy preserving federated learning for proton exchange membrane fuel cell," Renewable and Sustainable Energy Reviews, Elsevier, vol. 212(C).
    4. Ji, Zhixing & Qin, Jiang & Cheng, Kunlin & Zhang, Silong & Wang, Zhanxue, 2023. "A comprehensive evaluation of ducted fan hybrid engines integrated with fuel cells for sustainable aviation," Renewable and Sustainable Energy Reviews, Elsevier, vol. 185(C).
    5. Mao, Jingwen & Wang, Enhua & Wang, Hewu & Ouyang, Minggao & Chen, Youpeng & Hu, Haoran & Lu, Languang & Ren, Dongsheng & Liu, Yadi, 2023. "Progress in metal corrosion mechanism and protective coating technology for interconnect and metal support of solid oxide cells," Renewable and Sustainable Energy Reviews, Elsevier, vol. 185(C).

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