Carbon capture and storage through molten carbonate fuel cells systems: feasibility study and optimization through simulation and experimental work

This thesis investigates Molten Carbonate Fuel Cells (MCFCs) as a dual-purpose technology uniquely capable of simultaneously generating electricity and capturing carbon dioxide (CO₂). This intrinsic feature makes MCFCs a highly promising solution for carbon mitigation. The research focuses particularly on their potential application within the maritime sector and aligns with the increasing global drive toward decarbonisation, supported by new regulatory frameworks such as the International Maritime Organization (IMO) directives, the European Union Emissions Trading System (EU ETS), and FuelEU Maritime, which are setting ambitious CO₂ reduction targets and imposing carbon costs. The work has been developed along two complementary research paths: an experimental investigation and a system-level analysis. From the experimental perspective, the study focused on the development and characterization of key MCFC components, with particular attention to identifying manufacturing routes suitable for future industrial scale-up. In particular, the matrix, that is a crucial element that separates the electrodes and hosts the electrolyte, enabling ion transport, was optimized to achieve competitive performance using environmentally compatible materials and an innovative formulation was designed and produced. All fabrication and testing activities were carried out within the Caplab laboratory, a joint research facility between the University of Genoa and the company Ecospray Technologies, and further performance assessments were conducted at the Royal Institute of Technology (KTH) in Stockholm during an international research period. The performed tests achieved power densities higher than values typically reported in the literature, thereby confirming the effectiveness of the developed materials and fabrication procedures. From the system-level standpoint, a simulation-based study was performed to explore the integration of MCFC technology within Onboard Carbon Capture and Storage (OCCS) systems. Starting from literature-based layouts, several improvements and process optimizations were introduced, including gas recirculation strategies. A comparative analysis based on key performance indicators (such as electrical efficiency, fuel demand, system complexity, and spatial requirements) highlighted the strengths and trade-offs of different configurations, considering different net CO2 capture rates. Finally, the applicability of MCFC-based systems was evaluated for carbon-intensive industrial sectors, such as steel production, to assess their performance when treating carbon-rich off-gases under oxygen-deficient conditions. Overall, this thesis demonstrates the potential of MCFC technology as a promising solution for carbon capture and energy conversion, combining experimental advances in sustainable materials with system-level insights that pave the way for future large-scale applications