Solid Oxide Fuel Cells for AI Data Centers: Materials Durability, System Reliability, and Prospects for On-Site Firm Power

Artificial intelligence (AI) data centers are creating large, power-dense loads, often faster than transmission lines, substations, transformers, and grid interconnections can be expanded. This review assesses whether solid oxide fuel cells (SOFCs) can provide dependable on-site power during these grid delivery constraints and remain competitive after grid capacity becomes available. We critically synthesized evidence on AI electricity demand, competing power supply options, SOFC efficiency and durability, commercial deployments, environmental impacts, thermal and electrical integration, and hybrid SOFC–battery–grid systems. We also performed a screening-level levelized cost of electricity sensitivity analysis covering natural gas prices, carbon costs, stack replacement, grid electricity prices, and the avoided cost of delayed grid access. The evidence indicates that commercial SOFC systems can achieve approximately 50–60% net electrical efficiency and scale modularly from 325 kW units to a planned deployment of up to 2.45 GW. A nominal 100 MW installation would require approximately 308 such modules and at least 3600 m2 of direct equipment area, excluding auxiliary systems and safety setbacks. However, multi-year durability targets of about 40,000 h, fuel and carbon price exposure, slow transient response, lifecycle methane emissions, and limited opportunities to use high temperature exhaust heat remain important constraints. The economic analysis indicates that avoided grid delay costs can justify SOFCs as bridge assets, whereas long-term retention requires competitiveness without this temporary benefit. SOFCs are therefore most suitable for sites that prioritize rapid access to firm power, modularity, reliability, and low local air pollutant emissions, rather than as a universal alternative to grid expansion.