A kW-class internal-manifolded molten carbonate fuel cell (MCFC) stack (52 cells) was assembled with inorganic adhesive under a suitable stacking pressure. The organic compounds in the matrices were burnt out under the conditions of slow and uniform elevation of temperature and big flow of oxygen gas in the stack. The stacking pressure dropped with elevating temperature. The output power of the stack at 150 mA cm(-2) was 1025.5 W when the reactant gas pressure and utilization were 0.5 MPa and 20%, respectively. The thermal-electrical efficiency of the stack was enhanced by increasing the pressure of the reactant. However, it was contrarily decreased when current density was increased. (c) 2006 Elsevier Ltd. All rights reserved.