Granted Patent B2

US 12,355,085 · App. 16/695,276 · Granted Jul 8, 2025

Inventors: Jonathan Rosen (Morristown, NJ); Timothy A. Barckholtz (Whitehouse Station, NJ); Heather A. Elsen (Bethlehem, PA); Gabor Kiss (Hampton, NJ); Lu Han (Beaumont, TX); Thomas M. Smith (Iselin, NJ); Sandipan K. Das (Spring, TX); Chao-Yi Yuh (New Milford, CT); Carl A. Willman (Newtown, CT); Timothy C. Geary (Stamford, CT); Keith E. Davis (Southbury, CT); Abdelkader Hilmi (Bethel, CT); Lawrence J. Novacco (Brookfield, CT)

Assignees: ExxonMobil Technology and Engineering Company; FUELCELL ENERGY, INC.

H01M4/8626H01M8/145H01M2008/147

Abstract

Claims (28)

1. A method for producing electricity in a molten carbonate fuel cell, the method comprising:

introducing an anode input stream comprising H2, a reformable fuel, or a combination thereof into an anode gas collection zone, the anode gas collection zone being defined by an anode surface, a first separator plate, and an anode collector providing support between the anode surface and the first separator plate;

introducing a cathode input stream comprising O2 and CO2 into a cathode gas collection zone, the cathode gas collection zone being defined by a cathode surface, a second separator plate, and a cathode collector providing support between the cathode surface and the second separator plate; and

operating the molten carbonate fuel cell at a transference of 0.95 or less, a CO2 utilization of at least 75% and an average current density of 60 mA/cm2 or more to generate electricity, an anode exhaust comprising H2, CO, and CO2, and a cathode exhaust comprising 2.0 vol% or less CO2, 1.0 vol% or more O2, and 1.0 vol% or more H2O,

wherein 45% or more of the cathode collector is an open area, wherein the open area is a portion of the cathode collector not in contact with the cathode surface.

2. The method of claim 1 , wherein an average contact area diffusion length is 1.0 mm or less, or a contact area of the cathode collector with the cathode surface is greater than 10% of a total surface area of the cathode surface, or a combination thereof.

3. The method of claim 1 , wherein the cathode surface comprises one or more grooves.

4. The method of claim 3 , wherein 2% or more of the open surface area corresponds to the one or more grooves.

5. The method of claim 1 , wherein the transference is 0.90 or less.

6. The method of claim 1 , wherein 50% or more of the cathode collector is an open area.

7. The method of claim 1 , wherein an average cathode gas lateral diffusion length is 0.35 mm or less.

8. The method of claim 1 , wherein a voltage drop across the cathode is 0.4 V or less, or wherein the electricity is generated at a voltage of 0.55 V or more, or a combination thereof.

9. The method of claim 1 , wherein 75% or more of the cathode collector is an open area.

10. The method of claim 1 , wherein a H2 concentration in the anode exhaust is 5.0 vol% or more, or wherein a combined concentration of H2 and CO in the anode exhaust is 6.0 vol% or more, or a combination thereof.

11. The method of claim 1 , wherein a distance from any point on the cathode surface to an open area on the cathode surface is 1.0 mm or less.

12. The method of claim 1 , wherein the cathode input stream comprises 5.0 vol% or less of CO2, or wherein the cathode exhaust comprises 1.0 vol% or less of CO2, or a combination thereof.

13. The method of claim 1 , wherein the cathode exhaust comprises 1.0 vol% or less of CO2.

14. The method of claim 1 , wherein an open mesh screen having a mesh size of 1.0 mm or less average cell width and/or length is positioned between the cathode surface and the cathode collector.

15. A method for producing electricity in a molten carbonate fuel cell, the method comprising:

introducing an anode input stream comprising H2, a reformable fuel, or a combination thereof into an anode gas collection zone, the anode gas collection zone being defined by an anode surface, a first separator plate, and an anode collector providing support between the anode surface and the first separator plate;

introducing a cathode input stream comprising O2 and CO2 into a cathode gas collection zone, the cathode gas collection zone being defined by a cathode surface, a second separator plate, and a cathode collector providing support between the cathode surface and the second separator plate; and

operating the molten carbonate fuel cell at a transference of 0.97 or less, a CO2 utilization of at least 75%, and an average current density of 60 mA/cm2 or more to generate electricity, an anode exhaust comprising H2, CO, and CO2, and a cathode exhaust comprising 2.0 vol% or less CO2, 1.0 vol% or more O2, and 1.0 vol% or more H2O,

wherein 45% or more of the cathode collector is an open area, wherein the open area is a portion of the cathode collector not in contact with the cathode surface, wherein the cathode surface comprises one or more grooves, and wherein 2% or more of the open surface area corresponds to the one or more grooves.

16. The method of claim 15 , wherein the cathode exhaust comprises 1.0 vol% or less of CO2.

17. The method of claim 15 , wherein an open mesh screen having a mesh size of 1.0 mm or less average cell width and/or length is positioned between the cathode surface and the cathode collector.

18. The method of claim 1 , wherein the transference is 0.95 or less.

19. The method of claim 1 , wherein 50% or more of the cathode collector is an open area.

20. The method of claim 1 , wherein 75% or more of the cathode collector is an open area.

Assignments (1)

Continuity (2)

References Cited (400)