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R&D Status for Aerospace Fuel Cell Applications in Japan

March 27, 2015

Shunichi OKAYASenior Manager, Senior Fellow Office

Institute of Space and Astronautical Science (ISAS)

JAXA

Disclosed Version

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Contents

1. Introduction 2. JAXA Organization3. Fuel Cell Technologies for Aerospace Application4. Fuel Cell Technologies Development in JAXA4.1 Fuel Cell Application for HOPE 4.2 Fuel Cell Application for SPF Airship (HAA) and UAV4.3 Fuel Cell Application for Planetary Exploration

5. Conclusion

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1. Introduction

The fuel cell technology is being developed as the future promising ecological energy sources for the ground transportation systems applications and the terrestrial power plant applications under the big R&D funding of the government and the industries so far.

The fuel cell technology basis was originally developed for the spacecraft application (Gemini) about 50 years ago, and then this technology was applied to the main electric power system of Apollo spacecraft and Space Shuttle Orbiter because of its standalone higher performance capability (efficiency and power density).

JAXA is interested in this potential performance capability for the future aerospace power system applications, because the future aerospace system needs larger amount of electric power compared with that of the existing aerospace system

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Fuel Cell State of the Art Technology Overview;

Types of the fuel cell; 1) Alkaline type (AFC), 2) Phosphoric Acid Fuel Cell (PAFC), 3) Molten Carbonate Fuel Cell (MCFC), 4) Polymer Electrolyte Fuel Cell (PEFC) and 5) Solid Oxide Fuel Cell (SOFC).

The most advanced and matured fuel cell type is PEFC, because the major automotive manufactures selected the PEFC as the power plant for their first generation fuel cell vehicle (FCV).

SOFC has the highest efficiency capability, and has been demonstrated in several terrestrial power generation system applications.

However several key issues are still remaining for the real mass production.- Competitive Price- Fuel Supply and Storage

JAXA is studying the integrated propulsion and power system concept and technologies in order to compensate the fuel supply and storage issues.

3. Fuel Cell Technology for Aerospace Application

Nuvera “Andromeda-II” FC Stack

Ballard Mark 902 FC Stack

・37.5×80.5×25（H）cm（Volume：75 liters）

・Weight：96kg

・55×90×21（H)cm（Volume：78 liters）・Weight：140kg

・85（ｋW）（@DC 284（V）

・85（ｋW）（@DC 300（V））

・50×70×10（H）cm（Volume：34liters）

・Weight：90kg → 43kg

・85（ｋW）

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Nissan FC Stack

High pressure Compressed Gas Tank

Typical Automotive Fuel Cell Installation

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4. Fuel Cell Technologies Development in JAXA

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4.1 Fuel Cell Application for HOPE

1. Mission of HOPE; to access ISS as HTV currently does. 2. Configuration; unmanned and launched by H-2A/B3. Operation; Shuttle like reusable vehicle4. Key Feature; Non-toxic propellant was planned to be used.

3 sets of 10 KW Alkaline Fuel Cell are installed.

Courtesy NASA

Courtesy NASA

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4.1 Fuel Cell Application for HOPE

4. Fuel Cell for HOPE and More Electric HOPE (in 1996)

Space Shuttle has lots of fuel tanks inside;1. LH2 & LO2 for Alkaline Fuel Cell2. Hydrazine for APU3. MMH & NTO for OMS and RCS4. Hydraulic Oil for Controls

JAXA planned to apply the non-toxic fuel (methanol) as the common safer fuel for several subsystems.

JAXA planned to eliminate any hydraulics / pneumatics and to create “more electric system” concept.

Methanol Reforming PEM FC Electro-mechanical Actuators Methanol/LOX OMS and RCS Methanol E-APU

Courtesy NASA Courtesy NASA

Courtesy NASA

Courtesy NASA Courtesy NASA

4.2 Fuel Cell Application for SPF Airship and UAV - SPF Airship (HAA) Design Concept

Total weight; 32.4 ton

11 ton

FS - SPF Airship Design ConceptItems Specifications

245 m 61 m32.4 tons480,000 m3Solar cells/RFC 180 kWe 10 kWe30 m/s1 ton10 years

Feasibility Study completed in Fall 1999.

Mass breakdown of SPF airship

Power potential SC: 2g/W greater 17%RFC: greater 450 Wh/kg

RFC; 5.8 tonSC; 2.4 tonOthers; 3.1 ton

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Regenerative Fuel Cell is a high performance energy storage device.- RFC Concept:

Electric power generation by Fuel Cell(Discharge Phase)

+ Energy storage in the form of hydrogen and oxygen

gas made by Electrolyzer and stored in fuel tanks (Charge Phase)

- attractive potential features:1) Higher Energy Density (Lower Mass)2) Higher Cycle Life (at deep DOD)3) Shorter Charging Time (proportion to the electrical input)4) Clean Energy System ( Zero Emissions )

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計測時間（sec）

電力

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圧力

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ChargeDischarge

Typical RFC Operation

Regenerative Fuel Cell (RFC) Technology Overview

H2/O2 Pressure

Power Management

and Distribution

GH2Tank

GO2Tank

Power Management

and Distribution

Electric Power Bus

Water Tank

Electrolyzer Fuel cell

“Solar/Generator-RFC” Power System Concept

Solar array

Fig. Schematic - RFC Power Management Concept

Generator

Smart Grid / HAAOperation

Other Operation

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Discharge Time (H) ＠15KW & 30KW)

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15KW Output Power

30KW Output Power

RFC Potential High Power System Applications- Typical RFC Energy Density Capability -

Space Exploration

HAA/UAVSpacecraft

Aviation

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Discharge Time (H) ＠30KW)

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30KW Li Ion Battery

30KW RFC

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- RFC Bread Board Model (BBM) EvaluationRFC BBM high altitudes / lower pressure (0.1 bar) environment test was conducted in 2008

RFC Unit in Vacuum Chamber

Pressure Decay Profile

RFC Operation Data

H2/O2 Storage Pressure Profile

50 cycles RFC operation

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30 kW Aerospace Fuel Cell Power Unit Concept

Target energy density: 400 Wh/kg

30KW FC Stack

Water Tank

RFC Controller

Heat Exchanger

HP Electrolyzer

100cm80cm

120cm

30KW RFC Unit Mk3 (Higher Density)

Interface Panel

Units Specifications

Fuel cells

PEM type stackMax Power; greater 30kW

Electrolyzer

PEM type stackPower input 48 kW

Energy Storage

Al-liner/CFRP-FW at 5 to 10 MPaH2/O2 tanks 3900 L for 14hrs discharging.

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- RFC Flight Demonstration on B737 ecoDemonstrator conducted by Boeing / IHI / IA on October 2, 2012 -

(1) RFC power generation during taxing, climbing and level flight, and charging during level flight. (2.5 cycles operation was confirmed.)

(2) The emergency Hydrogen evacuation system was demonstrated.

Coffee brewed by RFC electric power during flight

2012.10.8 Aviation Week

Courtesy IHI/IA

Courtesy Boeing

Courtesy Boeing

The space systems mainly require the capable energy storage system; Battery vs. Fuel Cell (RFC)

Key factors are;- Higher energy density (Specific mass and volume)- Endurance to space and launch environments- Compact stowage to available space- Longer operation life

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4.3 Fuel Cell Application for Planetary Exploration

Lunar Lander

Advanced SpacecraftLunar/Mars Rovers

Mars Orbiter

Courtesy NASA

Courtesy NASA

Courtesy NASACourtesy NASA

Lunar Lander

Fuel Cell Power System Concept Designfor Lunar Base Applications

Fuel Cell Power System Design Goal(1) Energy Storage; 30KW*14days=10MWh(2) Mass; 14.5 ton(3) Energy Density; 700 Wh/kg (4) Rated Voltage; ～300Vdc

LO2 Tank LH2 Tank

Solar Cells & PMAD

FC Power Unit Pack

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Spacecraft Main Structure

2.7m

Mass Breakdown Summary; FCP; 1.6 ton LH2/LO2 storage; 2.1 ton Liquefier Sys; 1 ton Fuel; 7.4 ton Solar Cells / PMAD; 2.4 ton

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Spacecraft /Orbiter Configuration

H2/O2 Tanks

EC system

Main Structure

Center Cylinder Section

Solar Array Panel

Antenna

Fuel Cell Power System Concept Designfor Spacecraft Applications

FC system

Fuel Cell PS Design Goal(1) Energy Storage; 90KWh(2) Mass; 300kg(3) Volume; 400 litter(4) Rated Voltage; ～300Vdc

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5. Conclusion

JAXA conducted the fuel cell technologies development for several aerospace applications during past 20 years. However the flight prototypes have not yet existed. One of the reasons is the lack of the funding for the technologies development. Recently the most promising and excellent fuel cell state of the art technologies are demonstrated in the automotive or terrestrial programs. The collaboration with these commercial programs will bring lots of benefit to the aerospace high electric power systems advancement.

As the conclusion, I would like to promote the aerospace fuel cell power plant technologies early realization for the future high power system applications collaborating with the advanced commercial programs.