Fe–Ti microparticles and their oxidation and redox processes in chemical looping.

Metal oxide composites are enabling materials for many energy conversion systems such as chemical looping and photocatalysis.

Over the past several years, Nexceris has been developing high performance Solid Oxide Electrolysis Cells “SOEC” and stacks leveraging materials, electrode, and interlayer development along with Nexceris’ high power-density stack design. Observed performance and durability improvements demonstrated on both single cells and short stacks will be addressed. Stack intent cells with downselected electrode sets were scaled to both 42 and 96 cm2 active area cells. These were implemented into short-stacks and operated continuously in SOEC mode at ~1.3 V for ≥ 500 hours with <5%/kh degradation. The resulting subscale stack demonstrations provided promising baseline performance and a durability platform for future cell and stack development. RSOC tests were recently initiated with dynamic operation. Nexceris’ ChromLok coatings for bipolar plates were also integrated to stacks to enhance durability. This paper will provide a status update on Nexceris’ SOEC technology development.

With over 25 years of experience in solid oxide fuel cell (SOFC) materials, components and stack development, Nexceris has been rapidly expanding the technology portfolio. Development in Fuel Cell Materials, FlexCell and ChromLok technology are only a few examples. Stack testing capability up to 5 kW has been developed. Modular high-performance stack platforms that accommodate cells from 40 cm2 to 250 cm2 are being utilized, depending on customer requirements and system needs. Recently, Nexceris expanded its R&D efforts into solid oxide electrolysis cell (SOEC) technology. Initial performance of -1.5 A/cm2 and 500-hour durability tests at 1.3-1.4 V and 800 °C in short stacks show promising platform for further SOEC performance and durability improvements. Besides anode- and electrolyte- supported cell development, metal-supported cells (MSCs) have also been successfully developed at Nexceris and scaled to 250 cm2. The structure, performance and durability of MSCs are being continuously improved. Short 5-cell stacks are currently being demonstrated and the results will guide further stack development. A wide range of cell and stack technology developed at Nexceris provides capability to tailor cells and stacks based on user applications, whether those include continuous non-interrupted stationary operation or dynamic operation such as rapid thermal and redox cycling in mobile applications.

Nexceris has been active in the development of solid oxide fuel cell (SOFC) technology since 1995. In recent years, advancements have been achieved through innovations in SOFC stack materials, design, and operation. These advancements have increased technical maturity, improved durability, and reduced stack cost. With high current density (0.5–0.7 A/cm²) and single pass fuel utilization (70–80%) capabilities, Nexceris’ lightweight SOFC stacks are enabling for power systems that require both high gravimetric power density and electrical efficiency. Moreover, Nexceris’ SOFC technology has been demonstrated to be resilient against large thermal gradients and rapid load changes. Current SOFC work at Nexceris includes stack and system demonstrations, scale-up of stack manufacturing capabilities, and development of a 10-kW stack module. This paper will provide an update on the status and capabilities of Nexceris’ SOFC stack technology and cost-saving approaches to stack fabrication.