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.

In various aspects, systems and methods are provided for operating molten carbonate fuel cells with processes for iron and/or steel production. The systems and methods can provide process improvements such as increased efficiency, reduction of carbon emissions per ton of product produced, or simplified capture of the carbon emissions as an integrated part of the system. The number of separate processes and the complexity of the overall production system can be reduced while providing flexibility in fuel feed stock and the various chemical, heat, and electrical outputs needed to power the processes.

Molten carbonate fuel cell configurations are provided that allow introduction of an anode input gas flow on a side of the fuel cell that is adjacent to the entry side for the cathode input gas flow while allowing the anode and cathode to operate under co-current flow and/or counter-current flow conditions. Improved flow properties can be achieved within the anode or cathode during co-current flow or counter-current flow operation by diverting the input flow for the anode or cathode into an extended edge seal region (in an extended edge seal chamber) adjacent to the active area of the anode or cathode, and then using a baffle to provide sufficient pressure drop for even flow distribution of the anode input flow across the anode or cathode input flow across the cathode. A second baffle can be used to create a pressure drop at the anode or cathode exit.

A reforming element for a molten carbonate fuel cell stack and corresponding methods are provided that can reduce or minimize temperature differences within the fuel cell stack when operating the fuel cell stack with enhanced CO.sub.2 utilization. The reforming element can include at least one surface with a reforming catalyst deposited on the surface. A difference between the minimum and maximum reforming catalyst density and/or activity on a first portion of the at least one surface can be 20% to 75%, with the highest catalyst densities and/or activities being in proximity to the side of the fuel cell stack corresponding to at least one of the anode inlet and the cathode inlet.

An assembly includes (a) an anode-side sub-assembly including: a plate member having first and second opposing surfaces compatible with fuel and oxidant gases, respectively, the plate member having first and second opposing end segments, and third and fourth opposing end segments; an anode current collector abutting the first surface of the plate member; and first and second anode wet seal members releasably secured to the plate member so as to form first and second pockets on the first surface of the plate member and (b) a cathode-side subassembly comprising: first and second cathode wet seal members configured to form third and fourth pockets on the second surface of the plate member and to be releasably positioned adjacent said third and fourth opposing end segments; and a cathode current collector cooperating with the first and second cathode wet seal members.

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.

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.sub.2, Mn.sub.2O.sub.3, TiO.sub.2, ZrO.sub.2, Fe.sub.2O.sub.3, LiFe.sub.2O.sub.3, 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.

Systems and methods are provided for capturing CO.sub.2 from a combustion source using molten carbonate fuel cells (MCFCs). At least a portion of the anode exhaust can be recycled for use as a fuel for the combustion source. Optionally, a second portion of the anode exhaust can be recycled for use as part of an anode input stream. This can allow for a reduction in the amount of fuel cell area required for separating CO.sub.2 from the combustion source exhaust and/or modifications in how the fuel cells can be operated.

A drive system (1) having a unipolar machine (2) and a fuel cell (3) for supplying the unipolar machine (2) with electrical energy. The fuel cell (3) can be arranged in a ring shape around a rotor shaft (5) of a rotor (4) of the unipolar machine (2). The unipolar machine (2) can be provided in a motor vehicle (600) to supply a traction torque.

In various aspects, systems and methods are provided for operating a molten carbonate fuel cell assembly at increased power density. This can be accomplished in part by performing an effective amount of an endothermic reaction within the fuel cell stack in an integrated manner. This can allow for increased power density while still maintaining a desired temperature differential within the fuel cell assembly.