Systems and methods are provided for incorporating molten carbonate fuel cells into a heat recovery steam generation system (HRSG) for production of electrical power while also reducing or minimizing the amount of CO.sub.2 present in the flue gas exiting the HRSG. An optionally multi-layer screen or wall of molten carbonate fuel cells can be inserted into the HRSG so that the screen of molten carbonate fuel cells substantially fills the cross-sectional area. By using the walls of the HRSG and the screen of molten carbonate fuel cells to form a cathode input manifold, the overall amount of duct or flow passages associated with the MCFCs can be reduced.

A carbon dioxide capture system includes a fuel cell assembly comprising an anode section and a cathode section; an electrochemical hydrogen separator (EHS) configured to receive an anode exhaust stream from the anode section of the fuel cell assembly, and generate a first EHS output stream comprising hydrogen, and a second EHS output stream comprising concentrated carbon dioxide; and a liquid-vapor separator (LVS) configured to receive the second EHS output stream, and separate the second EHS output stream into a first LVS output stream comprising liquid carbon dioxide, and a second LVS output stream comprising non-condensable gases in the second EHS output stream and carbon dioxide vapor.

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.

An anode for a molten carbonate fuel cell (MCFC) having improved creep property by adding CeO.sub.2 and/or Cr for imparting creep resistance to nickel-aluminum alloy and nickel as materials for an anode is provided. Improved sintering property, creep property and increased mechanical strength of a molten carbonate fuel cell may be obtained accordingly.

Embodiments of methods for capturing high-purity CO.sub.2 in a hydrocarbon facility and related systems are provided. The method comprises operating a hydrogen plant to generate a high-purity hydrogen stream and a CO.sub.2 rich stream with a CO.sub.2 concentration above 30%; introducing the high-purity hydrogen stream into an anode of a molten carbonate fuel cell; introducing the CO.sub.2 rich stream and O.sub.2 into a cathode of the molten carbonate fuel cell; reacting CO.sub.2 and O.sub.2 within the cathode to produce carbonate and a cathode exhaust stream from a cathode outlet; reacting carbonate from the cathode with H.sub.2 within the anode to produce electricity and an anode exhaust stream from an anode outlet, the anode exhaust stream comprising CO.sub.2 and H.sub.2O; separating the CO.sub.2 in the anode exhaust stream in one or more separators to form a pure CO.sub.2 stream and a H.sub.2O stream; and collecting the pure CO.sub.2 stream.

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.

The objective of the present invention is to provide, in an industrially advantageous method, -lithium aluminate which has various favorable physical properties as a MCFC electrolyte holding plate with excellent heat stability and chemical stability, even when the -lithium aluminate is minute with the BET specific surface area being 10 m2/g or greater. A method for producing -lithium aluminate is characterized by mixing hydrated alumina and lithium carbonate in an Al/Li molar ratio of 0.95-1.01 and subjecting the obtained mixture (a) to a first firing reaction to obtain a fired product, and then subjecting a mixture (b) which is the obtained fired product to which an aluminum compound is added to a second firing reaction.

Systems and methods for generating electrical power combine pressurized fluidized bed combustors (PFBC) and molten carbonate fuel cells (MCFC) to provide a low cost solution for electricity generation with CO.sub.2 capture. A solid fuel is introduced fuel into a pressurized fluidized bed combustor to produce steam, a first quantity of electrical power, and a flue gas including CO.sub.2. Air, natural gas, at least a portion of the steam and at least a portion of the flue gas including CO.sub.2 are introduced to a molten carbonate fuel cell to produce a second quantity of electrical power and an output stream comprising primarily CO.sub.2. The pressurized fluidized bed combustor can desirably be air-fired and the solid fuel introduced there into can desirably be in a finely pulverized form.

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 m.

A method of forming a bipolar separator assembly for use in a fuel cell assembly includes a step of forming an anode-side sub-assembly, which comprises sub-steps of: providing an anode current collector, providing a plate member, first and second opposing end segments and third and fourth opposing end segments, positioning said plate member so that said anode current collector abuts the first surface of the plate member, providing first and second anode wet seal members, and releasably securing the first and second anode wet seal members to the plate member; a step of forming a cathode-side sub-assembly, which comprises sub-steps of: providing a cathode current collector; providing first and second cathode wet seal members; and releasably securing the first and second cathode wet seal members to the cathode current collector; and a step of assembling the cathode-side sub-assembly with the anode-side sub-assembly.