Novel Internal Dry Reforming Solid Oxide Fuel Cell Technology for CO2 Utilization

Reimagining Carbon Conversion Through Fuel Cell Innovation

Funded through the Grand Challenge: Innovative Carbon Uses in 2014, the University of Alberta project aimed to develop a solid oxide fuel cell (SOFC) technology that transforms carbon dioxide from a climate liability into a valuable resource. At the core of the project is a novel internal dry reforming process that enables SOFCs to simultaneously convert CO₂ and methane into electricity and syngas, a carbon monoxide-rich gas used in the production of fuels and industrial chemicals. Unlike conventional carbon capture methods that store CO₂, this system actively consumes it, offering a dual benefit of emissions reduction and energy generation. The technology is designed to operate at high temperatures, where dry reforming is most efficient, and leverages advanced materials and layered cell structures to overcome long-standing challenges such as catalyst degradation, carbon coking and sulfur poisoning.

The team engineered two distinct types of fuel cells—proton-conducting and oxygen-ion conducting—each optimized for performance and durability in harsh chemical environments. By integrating sulfur and coke-resistant catalysts directly into the anode structure, the cells demonstrated exceptional stability and efficiency, even when operating with biogas or sour gas streams. In testing, the proton-conducting SOFC achieved CO₂ conversion rates exceeding 90 per cent and maintained stable output over 100 hours of continuous operation. Meanwhile, the oxygen-ion variant, enhanced with a NiSn alloy catalyst, delivered high power density and strong resistance to sulfur contamination. Together, these innovations represent a significant leap forward in carbon-to-value technology.

Scaling Toward Industrial Integration

Building on its technical success, the project also addressed the practical challenges of scaling the technology for real-world deployment. Researchers designed and tested small SOFC stacks that demonstrated consistent power generation and stable performance under industrially relevant conditions. A custom-built lab-scale extruder was developed to fabricate the ceramic tubes efficiently, laying the groundwork for mass production. The team also explored integration with CO₂ capture systems, envisioning a closed-loop process where captured emissions are directly converted into energy and chemical feedstocks. With the potential to eliminate more than 1.6 tonnes of CO₂ per megawatt-hour of electricity produced, this technology offers a compelling pathway for industries seeking to reduce emissions while generating value.

What’s next?

Despite its technical promise and the successful demonstration of small-scale stacks and catalyst innovations, the technology has not yet transitioned into commercial deployment. No major industrial partnerships or pilot-scale installations have been reported, and the system remains at a pre-commercial stage. While six patents have been filed, the technology has not progressed significantly towards commercial adoption.