Advanced Net-Shape Insulation for Solid Oxide Fuel Cells

73138S03-I As solid oxide fuel cell technology matures, it is becoming increasingly important to lower the cost of insulation. Currently available low-cost insulation cannot be used in these applications because it contains silica, which volatilizes and degrades the anode. Therefore, new low-cost, net-shape options for solid oxide fuel cell insulation are needed. This project will develop a novel castable ceramic material with properties that make it ideal for solid oxide fuel cell insulation. These properties include net-shape fabrication capability, very low thermal conductivity, thermochemical stability up to 1000oC, and very good thermal shock resistance. Phase I will demonstrate the feasibility of using the castable ceramic materials as fuel cell insulation through specific experiments. These experiments will address the thermochemical stability of the proposed materials under fuel rich environments, the scale-up issues for forming larger parts, and the performance of solid oxide fuel cells using the new insulation material at high temperature. Commercial Applications and Other Benefits as described by awardee: Commercial sales of insulation materials for solid oxide fuel cells should exceed $3 million by the year 2010. It is anticipated that these new materials can capture a 40% market share, leading to annual sales of over $1.25 million to solid oxide fuel cell manufacturers and system integrators.