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.

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.

In various aspects, molten carbonate fuel cell configurations are provided that include a reforming catalyst and alkali traps integrated with one or more structures within the anode gas-collection volume. The purpose of the reforming catalyst is to reform methane (or some other reformable fuel) into hydrogen. In operation, alkali metals may migrate from the fuel cell electrolyte into the anode. Unless trapped, the alkali metals may deactivate the reforming catalyst. The alkali trap prolongs the operating life of reforming catalyst within the anode volume by capturing some portion of the alkali metal in the anode gas-collection volume. This reduces an amount of alkali metal that interacts with the reforming catalyst in the anode gas-collection volume. The prolonged life of the reforming catalyst prevents a decrease in catalyst activity.