CERDEC Bottom Line: THE WARFIGHTER NS9/03 US ARMY CERDEC Fuel Cell Technology Dr. Ashok Patil US ARMY CERDEC Chief, Environmental Systems and Fuel Cell

CERDEC Bottom Line: THE WARFIGHTER NS9/03

US ARMY CERDECFuel Cell TechnologyUS ARMY CERDECFuel Cell Technology

Dr. Ashok PatilUS ARMY CERDEC

Chief, Environmental Systems and Fuel Cell BranchFort Belvoir, VA

2004 AAAS Symposium13 February 2004

Seattle, WA


THE AMERICAN WARFIGHTER:ARMY’S #1 CUSTOMER

THE AMERICAN WARFIGHTER:ARMY’S #1 CUSTOMER

The ARMY’S R&D programsare focused on developing critical, cutting edged equipment for the AMERICAN WARFIGHTERSso that they can accomplish their Mission quickly and effectively and return home safe.

The AMERICAN WARFIGHTERS are our BOTTOM LINE.

Copyright: Time Magazine, December 2003


OverviewOverview

1. Military Power Needs

2. Why Fuel Cells?

3. Military Applications

4. Soldier Power

5. Technology Evolution

6. Conclusions


American WarfightersAmerican Warfighters

“We had extreme difficulty moving with all our weight. If our movement would have been to relieve a unit in contact or a time sensitive mission we would not have been able to move in a timely manner. It took us 8 hours to move 5 clicks. [that's less than 1 mph]”

This is more than just a cartoon.

For our American Warfighters


Why Fuel Cells?Why Fuel Cells?

- Coalition Forces came within days of running out of batteries to power critical Army systems.

-Rechargeable batteries were encouraged but not used by troops.

-Warfighters need light-weight, high energy dense power systems.


Military Power SourcesMilitary Power Sources

Diesel Gen Sets

TPV

Fuel Cells

Microengines

Batteries

Hybrid Systems

Current Army Power Sources

Pacing Technologies

Future Army Power Sources

Power Users

Watts

MINI-UV

Power Sources

NO CURRENT SOLUTION:

CRITICAL GAP!

20W –3000W

NO CURRENT SOLUTION:

CRITICAL GAP!

20W –3000W

3-5kW

50W


Fuel Cell Technology forThe Modern Army

Fuel Cell Technology forThe Modern Army

Benefits of Fuel Cells in Military Applications

•Light WeightLight Weight •Longer, Lighter Missions

•Silent OperationSilent Operation •Stealth and ‘Silent Watch’ Ops

•Higher EfficiencyHigher Efficiency •Cogeneration Use, Improved Fuel Utilization


Army Vision for Military Fuel Cell Systems

Army Vision for Military Fuel Cell Systems

Soldier & Sensor Power (10-100W)

Combined Heat and Power ( >3000W )

Auxiliary Power Units (500-3000W)

Major Applications for Portable Fuel Cell Technology


Fuel Cells of Interest to the ArmyFuel Cells of Interest to the Army

Proton Proton Exchange Exchange MembraneMembrane

•Low Temperature Operation

•High Energy Density

•Efficient Operation (30-40% on reformed fuels).

•Quick Start

•Proven Reliability

•Low Acoustics and Vibration

•Pure Hydrogen Fuel

•Heat Rejection at Larger Sizes

•Sensitive to Contaminants

•Thermal Mismatch between reformers and stacks

•Soldier Power

•Sensors

•Silent Watch Auxiliary Power Units

Direct Direct MethanolMethanol

•Low Temperature Operation

•Direct Liquid Fuel

•High Energy Density


•Operation Below Freezing

•Longevity of Stack Materials

•Slow Start Time

•Methanol Crossover

•Soldier Power

•Sensors

Solid Solid OxideOxide

•Fuel Flexible Goal-Diesel/JP8

•Tolerance to Contaminants Except Sulfur


•High Temperature Operation

•Materials Problems

•On/Off Cycle Life

•Slow Start Time

•Only Early Prototype Exist

•Auxiliary Power Units

•Vehicle Power

•Combined Heat and power

Fuel Cell Advantages Challenges Applications


HydrogenHydrogen SourceSource

Diesel/ JP-8Diesel/ JP-8** (1300-5000Whr/kg) (1300-5000Whr/kg)

Gasoline/JP-4Gasoline/JP-4** (1200-5000Whr/kg) (1200-5000Whr/kg)

MethaneMethane** (2100-5600Whr/kg) (2100-5600Whr/kg)

Propane/ButanePropane/Butane** (1920-5000Whr/kg) (1920-5000Whr/kg)

EthanolEthanol** (1000-3000Whr/kg) (1000-3000Whr/kg)

MethanolMethanol** (800-2300Whr/kg) (800-2300Whr/kg)

Chemical/Metal Hydrides (1200Whr/kg)Chemical/Metal Hydrides (1200Whr/kg)

Hydrogen (1000-23,000Whr/kg)Hydrogen (1000-23,000Whr/kg)

Hydrogen DeliveryHydrogen Delivery

* Based on 15-40% Efficiency


Soldier and Sensor PowerSoldier and Sensor Power

Goal: Longer, Lighter Missions through Hybrid Systems.

Applications: Soldier Power, Robots\UAVs, Remote Sensors, Battery Chargers.

Technology:Direct Hydrogen Fed-Fuel CellsDirect Methanol Fuel CellsMethanol Reforming Fuel Cell Systems

Soldier Systems can use prepackaged liquid fuels such as Methanol


High Energy Dense FuelsHigh Energy Dense Fuels

High energy dense fuels, such as methanol, favor low-power systems over batteries for longer missions (12+ hours)!

Portable Power - Energy Density

0

10

20

30

40

50

60

0.00 12.00 24.00 36.00 48.00 60.00 72.00 84.00 96.00

Mission Length in Hours

Po

wer

Sys

tem

Wei

gh

t in

Po

un

ds

Rechargeable Battery

Primary Battery

PEM Fuel Cell w\ Chemical Hydride

Direct Methanol FC


CERDEC Goals for Soldier PowerCERDEC Goals for Soldier Power

Soldier Power SourceSoldier Power Source

PowerPower: 25W continuous: 25W continuous

Energy DensityEnergy Density: 1000Whr/kg for 72 : 1000Whr/kg for 72 hour mission.hour mission.

Portable Battery ChargerPortable Battery Charger

PowerPower: 150-500W: 150-500Wee , 28VDC , 28VDC

Weight:Weight: < 9.0kg, including 1000Whrs of fuel.

Hot-Swappable Fuel Cartridge

Temperature Range: 1C - 52C

Non-Detectable (aural) at 100 meters.


CERDEC Efforts in Soldier and Sensor Power

CERDEC Efforts in Soldier and Sensor Power

15W Monopolar DMFC

Present DMFC-20(Version 1.0):

• 20 W net power.

•1.75 kg (fuel cell and b.o.p.)

•460 Whr / kg system energy density

(including 1.0L ‘Neat’ Methanol).

Future DMFC-20(Version 1.1):

• 20 W net power, ruggedized housing.

•1.0 kg (fuel cell and b.o.p.)

•43% Less Weight

•620 Whr / kg system energy density

(including 1.0L ‘Neat’ Methanol).


Direct Methanol FuelCell Evolution

Direct Methanol FuelCell Evolution

11stst Generation (2001) Generation (2001)Smart Fuel Cell’s A-25 DMFC :25W, 22 lbs (10 kg) dry.2.5L ‘Neat’ Methanol Fuel Reservoir.

-55 hour Runtime.

22ndnd Generation (2003) Generation (2003)New Prototype C-25 DMFC: 25W, 2lbs (1.0kg) dry. -90% Weight Reduction!140Whr Internal Fuel Storage

-6 hour Runtime


Equivalent Power Sourcesfor 72 Hour, 20W MissionEquivalent Power Sourcesfor 72 Hour, 20W Mission

For 72 hour mission, current DMFC Technology shows vast weight savingsvast weight savings over military batteries.

• BA-5590 Lithium Sulfur Dioxide Batteries

• 17.6 Pounds (8kg)

• $0.56 per Watt-hour

• Ball DMFC 20W

Direct Methanol Fuel Cell

with two fuel canisters.

• 6.4 Pounds (2.9 kg)• $0.34 per Watt-hour*

*($10,000/unit, 3000 hour lifetime)

(0.75kg, 800Whr per methanol canister).


Lifetime Cost Estimates20W Continuous Load

Lifetime Cost Estimates20W Continuous Load

Estimates do not reflect reduced shipping and logistics costs!

BA5590 Battery Ball DMFC 20

Unit Cost 75.00$ Unit Cost 10,000.00$ Disposal Cost 25.00$ Lifetime 3000

Watt-Hour 180 Energy Produced 60000

$/Watt-Hour 0.56$ Fuel Canister Energy Density 800 Watt-Hour

Fuel Canisters Needed 75

333 batteries needed Unit Fuel Cost 10.00$ per canister

for 60,000 Whr Lifetime Fuel Costs 750.00$

Canister Disposal Costs 5.00$

Total Battery Cost 33,300.00$ Lifetime Canister Displ. Cost 375.00$

for 3000 Hours Unit Disposal Cost 30.00$

Maintenance Hours 450 15% of lifetime

Maintenace Cost 20.00$ $/hr

Total Maintenance Cost 9,000.00$

Spare Parts Package 500.00$ 5% total cost

Total Cost 20,655.00$ per unit

$ / Watt-Hour 0.34$

38% Cost SavingsFor 3000 Hours!


Microchannel Reactors• Enhanced Heat Transfer• Enhanced Mass Transfer• Economics of Mass Production• High Surface Area to Volume Ratio• Low pressure Drop Through Channels

Future Directions in Reformer DesignFuture Directions

in Reformer Design


Fuel Reformer SystemsFuel Reformer Systems

Innovatek Design Goals:

• 1000 We nominal

• Diesel Fuel

• Process: Steam Reforming

• Weight: < 30 kg; Volume < 50 Lfor entire Fuel Processing System

Diesel Reformer

Battelle Design Goals:

• 100-200 We nominal system

• Weight < 3.5 kg (dry); Volume < 2.5 L

• Including Fuel Cell Stack and BOP

• Fuel: Methanol

• Process: Steam Reforming

Methanol Reformer


C3 On-The-MoveCombat Vehicle

C3 On-The-MoveCombat Vehicle

Mobile Power Pac2kW Methanol Reforming

Fuel Cell System

•Weight: 265 lbs (120 kg)•Fuel: Methanol-Water •3.5 Gallon Fuel Capacity -6 hours operation time•Voltage: 24-28VDC•Noise: < 55dBA at 7 metersNoise: < 55dBA at 7 metersFuel Cell APU mounted on the roof of a C3 On-The-

Move Combat Vehicle. This APU provides power to electronic equipment during stealth operations.


Cogeneration Power and CoolingCogeneration Power and Cooling

Heat Actuated Heat Actuated CoolingCooling

HeatHeat

CoolingCooling

Export PowerExport Power

Fuel CellFuel Cell

2 to 3 kW Electric Power-2 to 3 kW Electric Power-12 to 18 kBTUh Cooling12 to 18 kBTUh Cooling

FeaturesFeatures•Silent Operation

•Power On-The-Move

• Cooling

• Exportable Power

•Reduced Fuel ConsumptionJP-8JP-8


Hybrid Fuel Cell Technology Challenges

Hybrid Fuel Cell Technology Challenges

Challenges

Lightweight

Compact

Rugged NBC SurvivableNon Detectable

Affordable

Commercial Off-the-Shelf

Hydrogen Supply

Reliable,Maintainable, Sustainable

Military TemperatureOperation

Environmentally Safe

Military SpecificMilitary Specific


1998 2002 2004 2006 2010+

Soldier & Sensor Power

PEMFC with Hydrogen TankPEMFC Hybrid System

100W PEMFCWith Tank H2.

20W PEMFCHybrid

Demonstrated During Field Exercises

2004 Status:

Diesel Solid Oxide Fuel CellsLogistic Fuel Reformers for PEMFC Systems

Diesel Reformer for PEMFC

Solid OxideFuel Cell APU

Component Development/Basic Research

Soldier & Sensor Power, Portable APU

Roadmap (to TRL 6) for Military Fuel Cell DemonstrationsRoadmap (to TRL 6) for Military Fuel Cell Demonstrations

Soldier & Sensor Power, Portable APU

PEMFC with Chemical Hydride Direct Methanol Fuel Cells

Methanol Reforming PEMFC System

20W DMFC

2kW Methanol Reforming PEMFC

system

Early Prototypes


ConclusionsConclusions

Main Military Applications for Portable Fuel Cells Are:•Soldier & Sensor Power, Auxiliary Power Units, and Cogeneration.

US Army CERDEC is at the forefront of cutting edge fuel cell technology for the military.

Fuel cells offer significant weight and cost savings over traditional military power sources

Main Technology Barriers to Military are:•Fuel Supply, Affordability, and Reliability/Durability in the Field.

Prepackaged Liquid Fuels (Methanol) Ideal for Low-Power Applications.


Back-UpBack-Up


Past CERDEC EffortsPast CERDEC Efforts

Soldier PowerCooling Module

1996

Snorkler - 1996

Methanol PoweredGenerator Set – 1984

DMFC 60W SystemDARPA Palm Power

2002

PPS 100W - 1998

CERDEC Fuel Cell Timeline

25W DMFC2002-2003

20W DMFC 20031000W Methanol

Reforming PEM - 2001


Absorption Cooling Efforts

• Microchannel flow/chemical mixing• Porous membrane technology• Better Efficiency• Smaller Size• Heat Actuated Breadboard System

Current Cogeneration EffortsCurrent Cogeneration Efforts

Fuel Cell Efforts •2 kW fuel cell auxiliary power unitfor mobile power generation.

•1 kW integrated fuel cell system with low sulfur diesel reformer.

• 1 kW low sulfur diesel fuel reformer.

1kW PEM Fuel cell with fuel reformer.

Expander/compressor Refrigerant Desorber

Documents

CERDEC Bottom Line: THE WARFIGHTER NS9/03 US ARMY CERDEC Fuel Cell Technology Dr. Ashok Patil US ARMY CERDEC Chief, Environmental Systems and Fuel Cell