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Description
The proposed project is focused on research and development oriented at constructing a Carbon Capture and Storage/Utilization (CCS) system based on molten carbonate fuel cells (MCFC) operating at flue gas stream, producing electricity and gas “Sabatier ready” for power-to-gas applications. Such a unit can be the key component of energy storage systems which realize the power-to-gas concept. In such systems the excess electricity from intermittent sources (wind and solar) is used to generate synthetic fuels. Additionally, MCFC aid in increasing the flexibility of operation of conventional power units, especially in the light of the expected frequent shutdowns as centally disposed units. Molten Carbonate Fuel Cells offer several advantages over amine installations which has an established position in the market. Project focuses on the concept development, design, construction and experimental studies of a prototype 10 kW-class system with MCFC stack, which exhibits carbon capture in excess of 90% for coal fired power in MCFC (with negative energy penalty –4 MW/kg), resulting in the additional power of approximately 30%. The MCFC stack has a modular design which makes it possible to integrate several of such units to built larger CCS systems. Carbon Dioxide can be later re-use for production of synthetic fuels using excess electricity from intermittent sources allows integration of the electrical and gas grids (sector coupling) which results in higher flexibility and security of supply of energy. Thanks to that the gas grid becomes energy storage systems. Importance of this aspect has to be noted with respect to large scale CCS. MCFC-based systems are built, contrary to other fuel cells which operated only in sub-kW scale.
Summary of project results
The project was focused on research and development oriented at constructing a Carbon Capture and Storage/Utilization (CCS) system based on molten carbonate fuel cells (MCFC) operating at flue gas stream, producing electricity and gas “Sabatier ready” for power-to-gas applications. Such a unit can be the key component of energy storage systems which realize the power-to-gas concept. In such systems the excess electricity from intermittent sources (wind and solar) is used to generate synthetic fuels. Additionally, MCFC aid in increasing the flexibility of operation of conventional power units, especially in the light of the expected frequent shutdowns as centally disposed units. Molten Carbonate Fuel Cells offer several advantages over amine installations which has an established position in the market. Project focuses on the concept development, design, construction and experimental studies of a prototype 10 kW-class system with MCFC stack, which exhibits carbon capture in excess of 90% for coal fired power in MCFC (with negative energy penalty –4 MW/kg), resulting in the additional power of approximately 30%. The MCFC stack has a modular design which makes it possible to integrate several of such units to built larger CCS systems. Carbon Dioxide can be later re-use for production of synthetic fuels using excess electricity from intermittent sources allows integration of the electrical and gas grids (sector coupling) which results in higher flexibility and security of supply of energy. Thanks to that the gas grid becomes energy storage systems. Importance of this aspect has to be noted with respect to large scale CCS. MCFC-based systems are built, contrary to other fuel cells which operated only in sub-kW scale.
The MOLCAR project addressed the growing need for effective carbon capture solutions in industrial settings. The goal was to develop and demonstrate a MCFC system capable of both generating electricity and efficiently capturing CO₂ from flue gases. With rising concerns about CO₂ emissions and the urgent need for cleaner energy technologies, this project sought to offer an innovative solution that integrates energy production with carbon capture. To achieve this, the project implemented several key activities. A novel dual-ionic conductive electrolyte was developed, designed to enhance CO₂ separation efficiency in the MCFC stack. This material breakthrough allowed the MCFC stack to be compatible with flue gases that have a lower CO₂ concentration, such as those emitted by gas turbines and internal combustion engines. The collaboration between SINTEF and the Warsaw University of Technology led to the successful creation and scaling-up of a new hybrid electrolyte, which was integrated into a 10 kW pilot installation. This MCFC stack demonstrated high performance in both electricity generation and CO₂ separation. The MCFC stack achieved 90% CO₂ separation efficiency while maintaining a 50% energy efficiency rate. These outcomes were made possible by the successful integration of advanced materials and the development of a portable Balance-of-Plant system by Fuel Cell Poland.
For end beneficiaries, particularly industries aiming to reduce their CO₂ emissions, the project offers a practical and scalable solution. The MCFC technology developed in this project is compact and highly efficient, making it suitable for integration into existing industrial processes without requiring significant infrastructure changes. The successful demonstration of this technology has paved the way for its further development and commercialization, offering industries a dual-benefit system of energy production and environmental preservation. By advancing the efficiency and scalability of MCFC systems, the project contributes to the global effort to mitigate climate change through cleaner energy solutions. The technology''s ability to capture CO₂ while producing electricity presents a valuable tool for industries seeking to comply with increasingly stringent emissions regulations, while also reducing their environmental footprint.
Summary of bilateral results
The bilateral partnership with the Norwegian partner, SINTEF, played a crucial role in the success of the MOLCAR project. SINTEF''s unique expertise in developing ceramic structures and investigating ionic conductivity, combined with their advanced laboratory equipment, was essential for the development of a new matrix for the MCFC. This collaboration allowed the project to achieve significant breakthroughs, particularly in the creation of dual-ionic conductive materials that are key to the efficiency of the MCFC system.The partnership enabled a fruitful exchange of knowledge and skills between the Polish and Norwegian teams. The shared results from the project, including the development of the new matrix, will be utilized by both parties for future work: Poland will focus on further MCFC development, while Norway will advance research into new electrolytes and CO₂ membranes. The collaboration has already led to the publication of four joint research papers and the submission of several common grant proposals, highlighting the effectiveness of the bilateral cooperation in generating meaningful scientific contributions.In addition to the tangible project results, the partnership has fostered a strong foundation for continued collaboration. The teams plan to further develop MCFC technology together in future projects, building on the successful outcomes of the MOLCAR project. This continued cooperation will not only advance research in both countries but also strengthen the broader European efforts to develop sustainable energy solutions and carbon capture technologies