Company Name: FuelCell Energy, Inc.
3 Great Pasture Road

Danbury, CT  06813-1305

Point of Contact: Chao-Yi Yuh
Phone: (203)825-6112
Email Address: cyuh@fce.com

Project Title: Advanced Ceramic Fibers for a Carbonate Fuel Cell
Project ID #: DE-FG05-93ER81512

Technology:

Under this SBIR, FCE developed an innovative approach to increase the strength of a thin electrolyte separator matrix, a critical component in carbonate fuel cell, by a factor of ten, while reducing the cost by more than 50%. This strength enhancement allows long-term demonstration of FCE’ s Direct FuelCell (DFC), an important step toward commercialization of this clean and highly efficient power generation technology.

Benefits:

FCE’s DFC is the most efficient fossil fuel power generators in the size range for distributed generation (57% LHV as opposed to <47% for existing products). It is virtually pollution free, allowing for easy siting and emits less greenhouse gas (carbon dioxide) resulting from the high efficiency. It operates at optimal temperature for employing low-cost commodity materials. It operates on a variety of fuels, for use in a wide range of applications and settings. It also provides high-quality heat by-product for additional energy efficiency. Therefore, it is expected that these unique power plants will have worldwide market penetration with positive impact on domestic employment and foreign trade balance. The electrolyte matrix successfully developed under this SBIR research increases life and availability of DFC and hence accelerates the commercialization of this clean and efficient power generation technology.

Applications:

It is being used as electrolyte separator in all FCE’s Direct FuelCell (DFC) products to enhance robustness of the power plant that improves life and availability of DFC under field operating conditions. It will be used in FCE’s three core products: a 300kW, a 1.5MW, and a 3.0MW, primarily in distributed generation, CHP (combined heat and power), and high-quality uninterruptible power source. Other applications of DFC incorporating this electrolyte matrix include 1) marine application, 2) specialty-fuel application utilizing ethanol, coal bed methane, municipal digester gas, and gasified wood and 3) ultra high-efficiency DFC/Turbine combined cycle system that can achieve electric efficiency greater than 70%. Benefits to Company:

FCE has brought carbonate fuel cell from the laboratory curiosity stage to a product of immense potential over a twenty-five year period. However, a robust electrolyte matrix is required to achieve sufficient life and availability. Due to the success of this program, FCE was able to raise over $250 million to launch its commercialization effort. FCE currently has 12MW order on DFC. Also, due to the success of this SBIR program, FCE received a prestigious Tibbetts award from US Small Business Administration in 2000. FCE’s DFC is a leading carbonate fuel cell product in the world and FCE, although a small business, has contributed to making the U.S. a world leader in fuel cells.