The optimal design of solid oxide and molten carbonate fuel cells integration with a CO₂ recycling unit: An attempt to reach a clean transition process

High-temperature Solid Oxide Fuel Cell (SOFC) technology has great potential as a clean and effective energy source. However, several issues have prevented their widespread adoption, like high operating costs, difficulty integrating with other components, and being sensitive to fuel contamination. In order to address these challenges, the main novelties of the present work are carbon capture and utilization for clean energy production, using the flue gas condensation process as a cost-effective and energy-efficient strategy, and the combination of Molten Carbonate Fuel Cells (MCFC) for increased energy efficiency and most effective component integration. The proposed novel system is also equipped with a gasifier and vanadium chloride unit for syngas and clean hydrogen production. The system's practicality is evaluated by analyzing the key performance indicators from thermodynamic, exergo-economic, exergo-environmental, and sustainability viewpoints. Also, the Sankey diagram is presented to investigate each component's effectiveness from the exergy destruction facet. According to the findings, at the most optimum design condition, the acceptable energy and exergy efficiencies of 61.06% and 50.66%, respectively, are achieved, revealing the system's effectiveness. The suggested system is also financially attractive since it achieves a reasonable levelized power cost of 17.6 $/MWh at a total cost of 44.1 $/h. The findings show that carbon dioxide recovery is crucial in reducing the pollutants due to the low emission index of 5.01 kg/GWh. Finally, the exergo-environmental index, environmental damage effectiveness, and exergy stability factor have equivalent values of 0.012, 0.59, and 0.54.