A direct carbon fuel cell DCFC system (5), the system comprising an electrochemical cell, the electrochemical cell (10) comprising a cathode (30), a solid state first electrolyte (25) and an anode (20), wherein, the system further comprises an anode chamber containing a second electrolyte (125) and a fuel (120). The system, when using molten carbonate as second electrolyte, is preferably purged with CO2 via purge gas inlet (60).

Disclosed are a method for supplying molten carbonate fuel cell with electrolyte and a molten carbonate fuel cell using the same, wherein a molten carbonate electrolyte is generated from a molten carbonate electrolyte precursor compound in a molten carbonate fuel cell and is supplied to the molten carbonate fuel cell.

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.

As integrated fossil fuel power plant and a method of operating the power plant is provided. The integrated fossil fuel power plant includes a gas turbine arrangement and a carbonate fuel cell having an anode side and a cathode side. The operating method for the integrated fossil fuel power plant includes partially expanding combustion gases in the gas turbine arrangement so that the temperature of the partially expanded combustion gases is optimized for reaction in the cathode side of the carbonate fuel cell, and feeding the partially expanded combustion gases at the optimized temperature to the cathode side of the carbonate fuel cell for reaction in the cathode side of the carbonate fuel cell.

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.

In various aspects, systems and methods are provided for integration of molten carbonate fuel cells with a Fischer-Tropsch synthesis process. The molten carbonate fuel cells can be integrated with a Fischer-Tropsch synthesis process in various manners, including providing synthesis gas for use in producing hydrocarbonaceous carbons. Additionally, integration of molten carbonate fuel cells with a Fischer-Tropsch synthesis process can facilitate further processing of vent streams or secondary product streams generated during the synthesis process.

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.

A direct carbon fuel cell (DCFC) has a conductive mesh between an anode and a cathode of the DCFC. The conductive mesh is positioned at a specified distance from the anode. As the DCFC is operated, a carbon/carbonate fluid flows through the conductive mesh and though the porous anode. If the rate of carbon introduced into the DCFC is greater than the amount consumed, carbon will build up on the surface on the anode. Once the carbon build-up reaches the mesh, a conductive path will be created between the mesh and anode. A controller in contact with the conductive mesh measures the resistance between the conductive mesh and the anode and when the measured resistance falls to or below a defined set-point indicating a resistance when a conductive path between the anode and conductive mesh has formed, the controller can send a carbon build-up detected signal, and/or execute mitigation actions to reduce the amount of carbon delivered to the cell.

As integrated fossil fuel power plant and a method of operating the power plant is provided. The integrated fossil fuel power plant includes a gas turbine arrangement and a carbonate fuel cell having an anode side and a cathode side. The operating method for the integrated fossil fuel power plant includes partially expanding combustion gases in the gas turbine arrangement so that the temperature of the partially expanded combustion gases is optimised for reaction in the cathode side of the carbonate fuel cell, and feeding the partially expanded combustion gases at the optimised temperature to the cathode side of the carbonate fuel cell for reaction in the cathode side of the carbonate fuel cell.

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.