The technological development trends, barriers, and environmental impact assessment of solid oxide fuel cell (SOFC) from a life cycle perspective

Solid oxide fuel cells (SOFCs), as a highly efficient and clean energy technology, have demonstrated significant advancements at the material, single-cell, stack, and system levels, particularly in enhancing efficiency, reducing costs, and extending operational lifespans. However, the reliance on rare materials and the complexity of manufacturing processes remain critical challenges for further development. This study systematically reviews 52 peer-reviewed articles from Web of Science, Scopus, and ScienceDirect to evaluate the application of Life Cycle Assessment (LCA) and Life Cycle Costing (LCC) in SOFCs. The findings reveal that environmental impacts are predominantly concentrated in the operational phase, primarily driven by fuel-related energy consumption and emissions. LCC analysis indicates that costs are significantly influenced by manufacturing, operation, and maintenance, although recycling rare materials, such as platinum, can help mitigate both environmental and economic footprints. Recycling SOFC components, particularly metals and ceramics, holds significant potential for reducing environmental impact and resource consumption. Current methods, such as hydrometallurgy and pyrometallurgy, achieve high recovery rates but face challenges related to environmental harm, cost, and material purity. Emerging technologies, including electrochemical methods and closed-loop recycling, offer promising alternatives by minimizing energy use and waste generation. While current studies predominantly employ “cradle-to-gate” or “cradle-to-grave” system boundaries, advancements in recycling technologies advocate for a “cradle-to-cradle” approach to capture the lifecycle impacts fully. However, the limited large-scale deployment of SOFCs has resulted in incomplete Life Cycle Inventory (LCI) data, particularly in the operation, maintenance, and end-of-life phases, thereby reducing the accuracy of assessments. Furthermore, the variability in indicator selection and methodologies underscores the need for more comprehensive approaches to balance environmental, economic, and safety benefits. To address these gaps, sensitivity analysis and standardized research frameworks are essential. These tools can provide robust scientific guidance for the sustainable development of SOFCs, enabling more accurate and reliable assessments. This review offers actionable insights for researchers, policymakers, and industry stakeholders to optimize SOFC technology and advance sustainable energy systems. © 2025 Elsevier Ltd.