Polarization studies and post analysis have been carried out for characterizing the electrochemical performance and processes affecting life and stability of carbonate fuel cell electrodes. Based on this understanding optimized electrodes design and new electrolyte composition were developed to improve cell performance and achieve the useful life of >5 years. The anode performance and stability were improved by developing an optimized microstructure with better electrolyte retention capabilities. Tests with an advanced electrolyte composition showed 25 mV improvement at 650°C and more than 45 mV at low temperatures compared to baseline. The NiO dissolution in advanced electrolyte is reduced by >60% compared to baseline electrolyte. Anode and cathode electrodes showed stable mechanical strength and stable electrochemical performance.

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