Fuelcell Energy, Inc.

Exxonmobil Technology and Engineering Company

Energy Research Corporation

The United States of America As Represented by the Department of Energy

Chao-yi Yuh

Mohammad Farooque

Abdelkader Hilmi

Arun Surendranath

Ramakrishnan Venkataraman

Dana Kelley

Timothy C Geary

Gabor Kiss

Timothy Andrew Barckholtz

Jonathan Rosen

Jin-Yun Wang

Jian Li

Carl A Willman

Ling Chen

Richard Johnsen

Chao M Huang

Matthew T Snider

April Corpuz

Lawrence J Novacco

Heather A Elsen

Sandipan K Das

Michael Primerano

Gengfu Xu

Fred C Jahnke

Matthew Lambrech

Thomas M Smith

Pinakin S Patel

Hossein Ghezel-Ayagh

Lu Han

Zhiwen Ma

Keith E Davis

Michael Cramer

Thomas M Lucas

Rodrigo F Blanco Gutierrez

Joel D Doyon

Daniela Nedu

Ethan L Demeter

Michael Alexander

William Beesley

Nikhil H Jalani

Tom X Jian

Dana A Kelley

Abedelkader Hilmi

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

Disclosed here is a supported catalyst comprising a thermally stable core, wherein the thermally stable core comprises a metal oxide support and nickel disposed in the metal oxide support, wherein the metal oxide support comprises at least one base metal oxide and at least one transition metal oxide or rare earth metal oxide mixed with or dispersed in the base metal oxide. Optionally the supported catalyst can further comprise an electrolyte removing layer coating the thermally stable core and/or an electrolyte repelling layer coating the electrolyte removing layer, wherein the electrolyte removing layer comprises at least one metal oxide, and wherein the electrolyte repelling layer comprises at least one of graphite, metal carbide and metal nitride. Also disclosed is a molten carbonate fuel cell comprising the supported catalyst as a direct internal reforming catalyst.

Supported nickel catalysts used as direct internal reforming catalyst in molten carbonate fuel cells

An end cell assembly for a fuel cell stack includes an end plate and at least two inactive anode parts disposed adjacent to the end plate. Each inactive anode part comprises a nickel foam anode disposed directly above an anode current collector and a separator sheet disposed 5 above the nickel foam anode.

Fuel cell inactive end cell design to improve electric and mechanical contact

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

A caulk composition includes: at least one powder component and at least one binder component. The powder component is a ball-milled powder component comprising ceria, zirconia, alumina, or a combination thereof. The powder component is a heat-treated powder component that has been heated to a temperature of at least 1500&#xb0; C. The powder component is present in a concentration range of 65 wt % to 75 wt % of the caulk composition. The powder component has a particle size distribution of 95% less than 25 &#x3bc;m and 90% greater than 1 &#x3bc;m. The binder component is present in a concentration range of 25 wt % to 35 wt % of the caulk composition.

Wet seal caulk with enhanced chemical resistance

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 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

An inorganic felt material includes zirconia stabilized by at least one Group IIA material, such that the Group IIA material includes at least one of calcium (Ca), magnesium (Mg), or a combination thereof. The felt material may also include at least one Group III material.

Ceramic felt material for high-temperature 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 cathode current collector is made from a composite material including a first metallic layer made of a first metal and a second metallic layer made of a second metal different from the first metal. The first metallic layer is cladded with the second metallic layer. The first metallic layer is configured to form a conductive oxide corrosion layer in the presence of oxygen, molten carbonate electrolyte, or a combination thereof. The second metallic layer is corrosion resistant.

Corrosion resistant current collector for high-temperature fuel cell

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

A high temperature electrolyzer assembly comprising at least one electrolyzer fuel cell including an anode and a cathode separated by an electrolyte matrix, and a power supply for applying a reverse voltage to the at least one electrolyzer fuel cell, wherein a gas feed comprising steam and one or more of CO2 and hydrocarbon fuel is fed to the anode of the at least one electrolyzer fuel cell, and wherein, when the power supply applies the reverse voltage to the at least one electrolyzer fuel cell, hydrogen-containing gas is generated by an electrolysis reaction in the anode of the at least one electrolyzer fuel cell and carbon dioxide is separated from the hydrogen-containing gas so that the at least one electrolyzer fuel cell outputs the hydrogen-containing gas and separately outputs an oxidant gas comprising carbon dioxide and oxygen.

Reformer-electrolyzer-purifier (REP) assembly for hydrogen production, systems incorporating same and method of producing hydrogen

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New Milford, CT, United States of America

Chao-yi Yuh