Towards greener MCFCs matrix: a new solvent for tape casting fabrication

Carbon capture and storage plays a fundamental role in achieving the ambitious goal of the 2030 Agenda to eliminate carbon dioxide emissions by 2050. One of the most promising technologies for this purpose is the Molten Carbonate Fuel Cell (MCFC), a device capable of producing energy while capturing carbon dioxide from industrial flue gases. In this technology, a key component is the ceramic matrix that is filled with molten carbonates. This work aims to optimize both its performance and the production process, with a focus on making it more environmentally friendly by eliminating toluene, a component commonly used in literature for its production. The developed matrix formulation was characterized using mercury porosimeter and scanning electron microscopy (SEM), revealing uniform morphology across the entire surface, with porosity and pore size distribution values consistent with those reported in the literature. Once the optimal physical properties were achieved, the electrochemical performance of the matrix was assessed through a comprehensive testing procedure using reference electrodes. Additional tests were carried out by varying the cathode gas composition and operating temperature, as well as replicating real industrial exhaust conditions that require effective CO₂ reduction solutions. In all test scenarios, the matrix exhibited performance values fully in line with literature benchmarks, confirming its potential and marking a significant improvement in the manufacturing process. Overall, this study provides a comprehensive link between manufacturing parameters, material properties, and electrochemical performance, contributing to the optimization of MCFC matrices for carbon capture applications.