Aliaksandr Martsinchyk

For efficient alkaline water-splitting, it is crucial to have bifunctional electrocatalysts that exhibit low overpotentials, durability, and the possibility of being produced through scalable methods. This study involved the use of screen printing to apply a porous nickel microparticle/polymer interlayer onto commercial nickel foam, which then acted as a base for the solvothermal growth of cobalt-based oxide/hydroxide nanostructures. The optimized electrode showed excellent bifunctional capabilities in 1 M KOH, requiring only 61 mV for the hydrogen evolution reaction and 241 mV for the oxygen evolution reaction at a current density of 10 mA cm⁻². In comparison, the control electrodes, such as those with cobalt directly deposited on unmodified nickel foam and screen-printed nickel foam substrates without cobalt, exhibited poorer overall performance. Although the cobalt-modified nickel foam exhibited a higher C_dl-derived apparent electrochemical surface area, the cobalt-modified screen-printed electrode achieved the best ECSA-normalized HER and OER responses, indicating that the enhancement in activity was not solely due to the capacitive surface area of the electrode. The increased integrated redox charge suggests a greater contribution from electrochemically accessible Co/Ni redox-active species, while impedance analysis supports a more favorable apparent interfacial response under the tested HER- and OER-relevant conditions. Long-term chronopotentiometry and post-stability SEM confirmed stable bifunctional operation.

Bifunctional electrocatalysts that offer low overpotentials, robustness, and potential compatibility with scalable fabrication routes are essential for effective alkaline water splitting. In this study, a porous nickel microparticle/polymer interlayer was applied to commercial nickel foam via screen printing, serving as a framework for the solvothermal growth of cobalt-based oxide/hydroxide nanostructures. The optimized electrode demonstrated strong bifunctional performance in 1 M KOH, requiring only 61 mV for the hydrogen evolution reaction and 241 mV for the oxygen evolution reaction at a current density of 10 mA cm^-2. In comparison, the control electrodes, such as those with cobalt directly deposited on unmodified nickel foam and altered nickel foam substrates without cobalt, exhibited poorer overall performance. Although the cobalt-modified unaltered nickel foam exhibited a higher C_dl-derived apparent electrochemical surface area, the cobalt-modified screen-printed electrode achieved the best ECSA-normalized HER and OER responses, indicating that the enhancement in activity was not solely due to the capacitive surface area. The increased integrated redox charge suggests a greater contribution from electrochemically accessible Co/Ni redox-active species, while impedance analysis supports a more favorable apparent interfacial response under the tested HER- and OER-relevant conditions. Long-term chronopotentiometry and post-stability SEM supported stable bifunctional operation.

The study examines the influence of diverse flue gas compositions on the operational parameters and efficiency of MCFCs (molten carbonate fuel cells) as CO₂ separation devices to provide foundational knowledge on MCFC operation under various industrial conditions. MCFCs inherently rely on the presence of CO₂ at the cathode, where it combines with oxygen to form carbonate ions that migrate through the electrolyte; thus, CO₂ acts as a carrier species rather than a fuel, enabling simultaneous electricity generation and CO₂ separation. The findings indicate that MCFCs are most effective when operated with CO₂-rich flue gases, such as those from coal and lignite-fired power plants with CO₂ contents of roughly 12–15 vol.% and O₂ contents of 2–6 vol.%. In these cases, CO₂ reduction rates of up to 80% can be achieved while maintaining favorable cell voltages. Under such conditions, relevant also for the cement industry (CO₂ between 15 and 35 vol.%), the Nernst voltage can reach about 1.18 V. In contrast, flue gases from gas turbines, which typically contain only 4–6 vol.% CO₂ and 11–13 vol.% O₂, result in lower Nernst voltages (0.6–0.7 V) and a decrease in efficiency. To address this issue, potential modifications to the MCFC electrolyte are suggested to enhance oxygen-ion conductivity and improve performance. By quantifying the operational window and CO₂-reduction potential for different sectors at 650 °C and 1 atm using a reduced-order model, the paper provides a technology assessment that supports sustainable industrial operation and the design of CCS (carbon capture and sequestration) strategies in line with climate goals.

High-temperature fuel cells and electrolyzers, particularly molten carbonate fuel cells (MCFCs) and Molten Carbonate Electrolyzers (MCEs), are expected to play a critical role in clean power generation, hydrogen production, and integrated CO₂ separation. Unfortunately, despite their potential, these technologies have not yet reached full commercialization. The main reason for this is material degradation. In particular, the corrosion of metallic components continues to be a leading cause of performance loss and system failure. This review provides a comprehensive assessment of degradation mechanisms in MCFC and MCE systems. It examines key metallic components, such as current collectors and bipolar plates, focusing on the performance of commonly used materials, including stainless steels and advanced alloys, under prolonged exposure to corrosive environments. To address degradation issues, this review evaluates current mitigation strategies and discusses material selection, protective coatings application, and the optimization of operational parameters. Advances in alloy development, coatings, surface treatments, and process controls have been compared in terms of effectiveness, scalability, and long-term stability. The review concludes with a synthesis of current best practices and future directions, emphasizing the need for integrated, multi-functional solutions to achieve the lifetimes required for full commercialization. By linking materials science, electrochemistry, and systems engineering, this review offers directions for the development of corrosion-resistant MCFC and MCE technologies in support of a hydrogen-based, carbon-neutral energy future.

The article describes a mathematical model of methanol steam reforming taking place at the anode of a molten carbonate fuel cell (MCFC). An artificial neural network with an appropriate structure was subjected to a learning process on the data obtained during an experiment on the laboratory stand for testing high-temperature fuel cells located at the Institute of Heat Engineering of the Warsaw University of Technology. The backpropagation of error method was used to train the neural network. The training data included the results of methanol steam reforming in the fuel cell for steam-to-carbon ratios of 2:1, 3:1, and 4:1. The artificial neural network was then asked to generate results for other steam-to-carbon ratios. As a result, the artificial neural network predicted that the highest power density for a molten carbonate fuel cell working on methanol would be obtained with a steam-to-carbon ratio of 2.8:1. The article’s key achievement is the application of artificial intelligence to calculate an unusual steam-to-carbon ratio for the methanol steam reforming process occurring directly at the anode of an MCFC fuel cell. The solution proposed in the article contributed to reducing the number of experimental studies.

This work presents an advanced computational fluid dynamics (CFD) model of a 5 kW molten carbonate fuel cell (MCFC) stack intended to provide a broad analysis and deliver improved design through optimizing flow distribution. The goal is to provide a variant analysis of flow distribution in the internal channels through the CFD model. SolidWorks was used to design the MCFC stack, and SOLIDWORKS^® Flow Simulation was utilized to model the flow distribution inside the stack. The simulated stack was validated through an experimental investigation of a 5 kW MCFC stack, empirically measuring pressure and flow distribution in an experimental laboratory station optimized for multi-scale fuel cell stack testing. The test was designed to examine a variety of internal flow distribution factors. The verified CFD model was employed for sensitivity analysis on various scales. To enhance the design, the influence of stack and single-cell constructional characteristics on the 5 kW MCFC was investigated.

E-fuels, or synthetic fuels produced from green hydrogen and captured CO₂, are a promising solution for achieving climate neutrality by replacing fossil fuels in transportation and industry. They help reduce greenhouse gas emissions and efficiently utilize renewable energy surpluses. This study aims to assess the current state and future potential of e-fuel production technologies, focusing on their scalability and market integration. A comprehensive literature review and market trend analysis, including modeling based on historical data and growth forecasts, were used to estimate market penetration. Results indicate that e-fuels could reach a 10% market share within the next 5 years, potentially reaching 30% in 20 years, particularly in aviation, maritime transport, and the steel industry. Ongoing projects expected to be completed this decade may cover about 20% of the global liquid fuel demand for transportation. However, challenges such as high costs, scalability, and recent project terminations due to funding shortages highlight the need for substantial investment, regulatory support, and innovation. Global collaboration and policy alignment are essential for the successful development and integration of e-fuels as a critical pathway to decarbonization.

This work presents an advanced CFD model of a 5kW Molten Carbonate Fuel Cell stack intended to provide a broad analysis and deliver improved design through optimizing flow distribution. The goal is to provide variant analysis of flow distribution in the internal channels through the CFD model. SolidWorks was used to design the MCFC stack, and SOLIDWORKS® Flow Simulation was utilized to model the flow distribution inside the stack. The simulated stack was validated through an experimental investigation of a 5kW MCFC stack, empirically measuring pressure and flow distribution in an experimental laboratory station optimized for multi-scale fuel cell stack testing. The test was designed to examine a variety of internal flow distribution factors. The verified CFD model was employed for sensitivity analysis on various scales. To enhance the design, the influence of stack and single-cell constructional characteristics on the 5 kW MCFC was investigated.

This manuscript discusses the advancements and historical development of solid oxide electrolysis (SOE), co-electrolysis, and methanation technologies, addressing the performance fundamentals and system integration challenges in the context of the EU’s 2050 climate neutrality goals. SOE technologies, characterized by their high efficiencies and ability to operate at elevated temperatures, offer significant advantages in hydrogen production and power generation. Co-electrolysis of steam and carbon dioxide in SOEs provides a promising pathway for syngas production, leveraging carbon capture and utilization strategies to mitigate carbon emissions. Additionally, catalytic methanation processes described within facilitate the synthesis of methane from carbon oxides and hydrogen, which could be integral to renewable energy storage and grid-balancing solutions. Historical analysis provides insights into the evolution of these technologies from early experiments to modern applications, including their role in space programmes and potential for industrial scale-up. The current state of research and commercialization, highlighted through various system designs and operational enhancements, suggests that SOEs are crucial for sustainable energy transformations, underscoring the necessity for continued innovation and deployment in relevant sectors.

This review thoroughly examines recent progress, challenges, and future prospects in the field of alkaline exchange membrane (AEM) electrolysis. This emerging technology holds promise for eco-friendly hydrogen production. It blends the benefits of traditional alkaline and proton-exchange membrane technologies, enhancing affordability and operational efficiencies by utilizing non-precious metal catalysts and operating at reduced temperatures. This study discusses key developments in materials, electrode design, and performance enhancement techniques. It also highlights the strategic role of AEM electrolysis in meeting global energy transition targets, like achieving Net Zero Emissions by 2050. An in-depth exploration of the operational fundamentals of AEM water electrolysis is provided, noting the technology’s early stage development and the ongoing need for research in membrane-electrode assembly assessment, catalyst efficiency, and electrochemical ammonia production. Moreover, this review compiles results on different cell components, electrolyte types, and experimental approaches, providing insights into operational parameters critical to optimizing AEM performance. The conclusion emphasizes the necessity for continuous research and commercialization efforts to exploit AEM electrolysis’s full potential across diverse industries.