Fuelcell Energy, Inc.

Exxonmobil Technology and Engineering Company

Eveready Battery Company, Inc.

Exxonmobil Research and Engineering Company

Abdelkader Hilmi

Chao-yi Yuh

Mohammad Farooque

Timothy C Geary

Arun Surendranath

Gabor Kiss

Jonathan Rosen

Heather A Elsen

John C Bailey

Timothy Andrew Barckholtz

Guanghong Zheng

Mark A Schubert

Carl A Willman

Jing Zhang

Chao-Yi Yuh

Gary R Tucholski

Richard A Langan

Andrew Webber

William Anthony Lamberti

Frank H Feddrix

William C Horn

Sandipan K Das

Anding Zhang

Frank B Tudron

Adam Franco

Ethan L Demeter

Thomas M Smith

Hossein Ghezel-Ayagh

Lu Han

Lawrence J Novacco

Keith E Davis

Rodrigo F Blanco Gutierrez

Richard Johnsen

Gengfu Xu

Chao-yi Yun

Molten carbonate fuel cell configurations are provided that include one or more baffle structures within the cathode gas collection volume. The baffle structures can reduce the unblocked flow cross-section of the cathode gas collection volume by 10% to 80%. It has been discovered that when operating a molten carbonate fuel cell under conditions for elevated COutilization, the presence of baffles can provide an unexpected benefit in the form of providing increased transference and/or increased operating voltage.

Flow field baffle for molten carbonate fuel cell cathode

Cathode collector structures and/or corresponding cathode structures are provided that can allow for improved operation for a molten carbonate fuel cell when operated under conditions for elevated COutilization. A cathode collector structure that provides an increased open area at the cathode surface can reduce or minimize the amount of alternative ion transport that occurs within the fuel cell. Additionally or alternately, grooves in the cathode surface can be used to increase the open area.

Cathode collector structures for molten carbonate fuel cell

Molten carbonate fuel cells (MCFCs) are operated to provide enhanced COutilization. This can increase the effective amount of carbonate ion transport that is achieved. The enhanced COutilization is enabled in part by operating an MCFC under conditions that cause transport of alternative ions across the electrolyte. The amount of alternative ion transport that occurs during enhanced COutilization can be mitigated by using a more acidic electrolyte.

Operation of molten carbonate fuel cells with enhanced COutilization

An elevated target amount of electrolyte is used to initially fill a molten carbonate fuel cell that is operated under carbon capture conditions. The increased target electrolyte fill level can be achieved in part by adding additional electrolyte to the cathode collector prior to start of operation. The increased target electrolyte fill level can provide improved fuel cell performance and lifetime when operating a molten carbonate fuel cell at high current density with a low-COcontent cathode input stream and/or when operating a molten carbonate fuel cell at high COutilization.

Operation of molten carbonate fuel cells with high electrolyte fill level

A layered cathode structure for a molten carbonate fuel cell is provided, along with methods of forming a layered cathode and operating a fuel cell including a layered cathode. The layered cathode can include at least a first cathode layer and a second cathode layer. The first cathode layer can correspond to a layer that is adjacent to the molten carbonate electrolyte during operation, while the second cathode layer can correspond to a layer that is adjacent to the cathode collector of the fuel cell. The first cathode layer can be formed by sintering a layer that includes a conventional precursor material for forming a cathode, such as nickel particles. The second cathode layer can be formed by sintering a layer that includes a mixture of particles of a conventional precursor material and 1.0 vol % to 30 vol % of particles of a lithium pore-forming compound. The resulting layered cathode structure can have an increased pore size adjacent to the cathode collector to facilitate diffusion of COinto the electrolyte interface, while also having a smaller pore size adjacent to the electrolyte to allow for improved electrical contact and/or reduced polarization at the interface between the electrolyte and the cathode.

Layered cathode for molten carbonate fuel cell

A molten carbonate fuel cell assembly includes a cathode electrode; an anode electrode; an electrolyte matrix disposed between the cathode electrode and the anode electrode; a cathode current collector abutting the cathode electrode; and a first electrolyte composition stored in the cathode electrode, the first electrolyte composition comprising a first mixture of a eutectic Li/Na carbonate electrolyte doped with one or more additive materials, wherein the one or more additive materials comprise one or more of SrO, BaCO, BaO, SrCO, and combinations thereof.

High-performance electrolyte for molten carbonate fuel cell

A binder solution for an electrolyte matrix for use with molten carbonate fuel cells is provided. The binder solution includes a first polymer with a molecular weight of less than about 150,000 and a second binder with a molecular weight of greater than about 200,000. The binder solution produces an electrolyte matrix with improved flexibility, matrix particle packing density, strength, and pore structure.

Binder for electrolyte matrix for molten carbonate fuel cells

A reinforced electrolyte matrix for a molten carbonate fuel cell includes a porous ceramic matrix, a molten carbonate salt provided in the porous ceramic matrix, and at least one reinforcing structure comprised of at least one of yttrium, zirconium, cerium or oxides thereof. The reinforcing structure does not react with the molten carbonate salt. The reinforced electrolyte matrix separates a porous anode and a porous cathode in the molten carbonate fuel cell.

Reinforced matrix for molten carbonate fuel cell and method for manufacturing the same

A method of making an electrolyte matrix includes: preparing a slurry comprising a support material, a coarsening inhibitor, an electrolyte material, and a solvent; and drying the slurry to form an electrolyte matrix. The support material comprises lithium aluminate, the coarsening inhibitor comprises a material selected from the group consisting of MnO, MnO, TiO, ZrO, FeO, LiFeO, and mixtures thereof, and the coarsening inhibitor has a particle size of about 0.005 &#x3bc;m to about 0.5 &#x3bc;m.

Stable electrolyte matrix for molten carbonate fuel cells

An electrolyte matrix for use with molten carbonate fuel cells having an enhanced stability and lifetime is provided. The electrolyte matrix includes lithium aluminate as a support material and a coarsening inhibitor. The coarsening inhibitor may be in the form of discrete particles or a dopant present in the support material. The coarsening inhibitor may include MnO, MnO, TiO, ZrO, FeO, LiFeO, or mixtures thereof. The coarsening inhibitor prevents the formation of large pores in the electrolyte matrix during operation of the fuel cell, increasing the performance and the service lifetime of the electrolyte matrix.

A composition for use in forming a fuel cell matrix includes a support material, an electrolyte material, and an additive material that includes a plurality of flakes having an average length in a range of 5 to 40 micrometers and an average thickness of less than 1 micrometer.

Fuel cell matrix composition and method of manufacturing same

A fuel cell matrix for use in a molten carbonate fuel cell comprising a support material and an additive material formed into a porous body, and an electrolyte material disposed in pores of the porous body, wherein the additive material is in a shape of a flake and has an average thickness of less than 1 &#x3bc;m.

A high-performance carbonate electrolyte for use in a molten carbonate fuel cell comprising a cathode electrode, an anode electrode, an electrolyte matrix and at least a cathode current collector abutting said cathode electrode, the high-performance carbonate electrolyte comprising: a first carbonate electrolyte stored in at least the cathode electrode of the molten carbonate fuel cell comprising a mixture of eutectic Li/Na carbonate electrolyte doped with one or more additive materials and one or more lithium precursors, wherein the additive materials include one or more of RbCO, CsCO, BaCO, LaO, BiO, TaOand mixtures thereof, and a second carbonate electrolyte stored in at least the cathode current collector, the second carbonate electrolyte having a composition that is the same or different from the first carbonate electrolyte.

High performance electrolyte for molten carbonate fuel cells comprising carbonate electrolyte doped with additive material(s) and lithium precursor(s)

A molten carbonate fuel cell cathode having a cathode body and a coating of a mixed oxygen ion conductor materials. The mixed oxygen ion conductor materials are formed from ceria or doped ceria, such as gadolinium doped ceria or yttrium doped ceria. The coating is deposited on the cathode body using a sol-gel process, which utilizes as precursors organometallic compounds, organic and inorganic salts, hydroxides or alkoxides and which uses as the solvent water, organic solvent or a mixture of same.

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Bethel, CT, United States of America

Abdelkader Hilmi